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

1

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 Operator’s 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

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A Foreword

Workshop manual DRF 400-450

A Foreword – Foreword

mm mm mm mm mm mm

3

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 machine’s 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.

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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 Operator’s Manual

page –

000262

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

Read the Operator’s Manual

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.

Read the Maintenance Manual

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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.

B

Safety

Keep in mind for your safety.

C

Preventive maintenance

Reference to maintenance manual: Preventive maintenance.

0

Complete machine

1

Engine

2

Transmission

3

Driveline/axle

4

Brakes

5

Steering

6

Suspension

7

Load handling

8

Control system

9

Frame, body, cab and accessories

10

Common hydraulics

11

Common electrics

12

Common pneumatics

D

Error codes

Error code information and instructions for reading error code information.

E

Schematics

Wiring diagrams, hydraulic diagrams and list of electrical components.

F

Technical data

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

G

Terminology and index

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

Technical description, comprehensive function descriptions and a description of the function of components included in the machine, divided into function groups. The components used for each 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).

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page –

A Foreword – Reading instructions

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.

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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.

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A Foreword – Reading instructions

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.

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A Foreword – Reading instructions

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NOTE All documents that accompany the machine are non-registered documents. No notification is made regarding changes.

Function descriptions

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.

1

10

2

3 9 4

8

5 7

000520

6

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A Foreword – Reading instructions

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)

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Symbol explanation function descriptions

1

2

The following symbols are used in function descriptions, the symbols are based on standard symbols used in wiring and hydraulic diagrams.

3

4

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

5

6

7

8

9

M

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

˚C

21

˚C

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

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A Foreword – About the documentation

About the documentation page –

Documentation sections The documentation to the machine comprises the following sections:

Operator’s manual The operator’s manual is supplied with the machine in the cab.

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

Supplementary documentation Supplementary documentation can be ordered for the machine.

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.

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A Foreword – Feedback

13

Feedback Form for copying

page –

Cargotec’s 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.

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

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

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

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

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

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

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A Foreword – Feedback

Workshop manual DRF 400-450

B Safety

1

B Safety

Table of Contents B Safety mm mm mm mm mm mm

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

Safety instructions ...................................................................................... 4 General ............................................................................................................. 4 Service position ................................................................................................. 4 Hydraulic and brake systems, 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

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B Safety

Workshop manual DRF 400-450

B Safety – Safety

mm mm mm mm mm mm

3

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 Operator’s 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.

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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

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B Safety – Safety instructions

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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.

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B Safety – Safety instructions

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.

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B Safety – Safety instructions

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7

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 engine’s fuel system operates at very high pressure. The pressure is so high that the jet can injure the skin, resulting in severe injuries. Risk of personal 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.

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B Safety – Safety instructions

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.

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B Safety – Safety instructions

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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 operator’s station, e.g., movement of lifting equipment, may cause severe personal injuries.

Safety precautions •

Make sure that the machine's lifting equipment is completely 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 you’re working with.

•

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

Working under machine

page –

Working under cab On machines with 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

A

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.

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B Safety – Safety instructions

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.

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B Safety – Safety instructions

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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.

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B Safety – Safety instructions

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. Today’s 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.

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B Safety – Safety instructions

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.

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B Safety – Safety instructions

Coolant The coolant in the machine’s 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 machine’s 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

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•

Use special instructions and equipment for refrigerant according to the manual when working on the air conditioning system. Special certification and authorisation is often required of the person who may do the work. (Note national legislation and local regulations!)

•

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

•

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

Workshop manual DRF 400-450

B Safety – Safety instructions

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.

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B Safety – Safety instructions

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 machine’s 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.

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Workshop manual DRF 400-450

B Safety – Safety instructions

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.

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B Safety – Safety instructions

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 aren’t 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 machine’s 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 machine’s 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 •

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Do not start work until the boom is lowered and fully retracted if possible.

Workshop manual DRF 400-450

B Safety – Safety instructions

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

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B Safety – Safety instructions

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.

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Workshop manual DRF 400-450

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.

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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.

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Workshop manual DRF 400-450

C Preventive maintenance – C Preventive maintenance

1

C Preventive maintenance

mm mm mm mm mm mm

page –

C Preventive maintenance 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.

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C Preventive maintenance – C Preventive maintenance

Workshop manual DRF 400–450

0 Complete machine

1

0 Complete machine

Table of Contents 0 Complete machine mm mm mm mm mm mm

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

Workshop manual DRF 400-450

3 4 5 5 7 8

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Workshop manual DRF 400-450

0 Complete machine – Complete machine

mm mm mm mm mm mm

page –

3

Complete machine Complete machine, description The Kalmar DRF 400–450 is a "Reachstacker" for container handling. The machine a lifting capacity of 40–45 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 attachment’s 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.

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page –

0 Complete machine – Complete machine

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 0–12 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 22–30 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 0–12. The function description contains information on which components are involved in the function and how these components work together. In some cases, there is information on what conditions are required in order for it to be possible to activate the function. Measurement points are marked with flags (C for measuring outlet, D for diagnostic menu).

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Workshop manual DRF 400-450

0 Complete machine – Complete machine

page –

5

Troubleshooting without an error code, example 1 Choose suitable section 0–12 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. It’s 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 0–12 there is function description, the function's included components and their position as well as, in certain cases, work instructions for how components are checked, cleaned or adjusted.

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0 Complete machine – Complete machine

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

NOTE The main electric power shall be turned off with the battery disconnector! 9 Disconnect the cable from the component in question. 10 Turn on the main electric power with the battery 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.

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

Check component.

Workshop manual DRF 400-450

Diagnostic menu

Function group

HYD, menu 5

4.1.2 Parking brake control

0 Complete machine – Complete machine

page –

7

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.

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0 Complete machine – Complete machine

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).

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Workshop manual DRF 400-450

1 Engine

1

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

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1 Engine

Workshop manual DRF 400–450

1 Engine

mm mm mm mm mm mm

page –

3

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 engine’s components and systems, refer to supplier documentation. References to component supplier documentation are only provided in exceptional cases. If information about a component is not found, the component supplier documentation should be used.

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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

P

rpm kph

II

D5

III

˚

D791-1 D10

Pa

10

7, 12

Pa

9

D8 8

006896

2

Pos

Explanation

Signal description

Reference

1

The pistol trigger on the control lever sends a voltage signal to the cab control unit (D790-1).

US815/T4 = 24 V

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

2

The cab control unit (D790-1) transmits weighing activated 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

3

Boom lowered to measuring position (when the boom is in measuring position boom lowering is interrupted automatically).

-

Lifting/lowering, function description page 11

4

The boom is operated to 60 cm extension (when the boom is in measuring position boom extension is interrupted automatically).

-

Extension, function description (hydraulic oil pump alternative Rexroth) page 37

5

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

Section 8 Control system, group 8.2.1.5 Sensor, boom angle

Control unit, frame rear (D797-R) transmits boom angle on the CAN bus.

Checked by control system, error shown with error code.

6

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D1: Diagnostic menu, see section 8 Control system group 8.4.9.2 ATTACH, menu 2

D5: Diagnostic menu, see section 8 Control system, group 8.4.10.4 OP, menu

Workshop manual DRF 400–450

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear D5: Diagnostic menu, see section 8 Control system, group 8.4.10.4 OP, menu

7 Load handling – 7.10.2 Weight indicator

183

Pos

Explanation

Signal description

Reference

7

The KID control unit (D795) activates the event menu fixed scale (flashing).

-

Section 11 Common electrics, group 11.5.3.12 KID control unit

8

Sensor, boom length 60 cm (B7224) sends a signal to the attachment control unit (D791-1).

U = 24 V

Section 8 Control system, group 8.2.1.6 Sensor, boom length

The attachment control unit (D791-1) transmits Boom length 60 cm on the CAN bus.

Checked by control system, error shown with 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 Control unit, frame front (D797-F).

U = 0.5 - 4.5 V

11

Control unit, frame front (D797-F) transmits weight information on the CAN bus.

Checked by control system, error shown with error code.

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

12

The KID control unit (D795) updates the weight information in the display (fixed glow).

-

Section 11 Common electrics, group 11.5.3.12 KID control unit

9

10

D8: Diagnostic menu, see section 8 Control system group 8.4.9.5 ATTACH, menu 5 Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D8: Diagnostic menu, see section 8 Control system group 8.4.9.5 ATTACH, menu 5

Lift cylinder hydraulic pressure sensor, description page 32 D10: Diagnostic menu, see section 8 Control system, group 8.4.10.3 OP, menu 3

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7 Load handling – 7.10.2 Weight indicator

Weight indicator, function description (product alternative dynamic scale)

page –

Condition

Reference value

Reference

Safety switch

Disengaged

Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage

1

7

D795

D797-F

D797-R D2

D4

6 Pa

Pa

Pa

Pa

2

3,5

m

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 SENSOR SUPPLY XY 24V SUPPLY,RPM>500 XY

Connection: signal from digital out D790-1/K10:9 to P708/+ and K358/ 86 Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter Signal value: 00

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.

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8 Control system – 8.4.1.8 CAN/POWER, menu 8

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). Circuit diagram: Circuit Power group 11.5

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 Function: 11.5.1.3 Ignition voltage (15) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

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.

0

No feed.

797-F FRAME, EME STOP POWER

page –

Description: Emergency stop voltage to Control unit, frame front (D797-F). Circuit diagram: Circuit Power group 11.5 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 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 1

Feed active.

0

No feed.

Workshop manual DRF 400–450

VDRF03.02GB

30

8 Control system – 8.4.1.9 CAN/POWER, menu 9

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 24V SENSOR SUPPLY XY 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

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.

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 24V SENSOR SUPPLY XY 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 Function: 11.5.1.3 Ignition voltage (15) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.1.11 CAN/POWER, menu 11

31

797-R FRAME, RED. POWER

page –

Description: Redundant voltage to Control unit, frame rear (D797-R). Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6 Connection: Le: redundant feed to D797-R/K2:7

000095

DIAG CAN/POWER 10(20) 797-R FRAME POWER XX.XXV RED.POWER Le X Ri X

Ri: redundant feed to D797-R/K2:8 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

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, frame rear (D797-R). Circuit diagram: Circuit OP + Scale group 8.2 000096

DIAG CAN/POWER 11(20) 797-R FRAME 24V SENSOR SUPPLY XY 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

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.

797-R FRAME, 5V REF

page –

Description: Reference voltage 5 V to sensors connected to Control unit, frame rear (D797-R). Circuit diagram: Circuit OP + Scale group 8.2 000096

DIAG CAN/POWER 11(20) 797-R FRAME 24V SENSOR SUPPLY XY 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).

Workshop manual DRF 400–450

VDRF03.02GB

32

8 Control system – 8.4.1.12 CAN/POWER, menu 12

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

DIAG CAN/POWER 12(20) 797-O FRAME POWER XX.XXV RED.POWER Le X Ri X EME STOP POWER X

Circuit diagram: Circuit Power group 11.5 Connection: 15-voltage from K315-1/30 via F54/4 and 58-2/4 to D797-O/K2:10 Function: 11.5.1.3 Ignition voltage (15) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

797-O FRAME, RED. POWER

page –

Description: Redundant voltage to Control unit frame option (D797-O). Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6 000097

DIAG CAN/POWER 12(20) 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 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

797-O FRAME, EME STOP POWER

page –

Description: Emergency stop voltage (15E) to Control unit frame option (D797-O). 000097

DIAG CAN/POWER 12(20) 797-O FRAME POWER XX.XXV RED.POWER Le X Ri X EME STOP POWER X

Circuit diagram: Circuit Power group 11.5 Connection: 15E-voltage from K3009-1/87 via K3009-2/87 and F58-3/ 4 to D797-O/K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value:

VDRF03.02GB

1

Feed active.

0

No feed.

Workshop manual DRF 400–450

8 Control system – 8.4.1.13 CAN/POWER, menu 13

8.4.1.13

33

CAN/POWER, menu 13

797-O FRAME, 24V SENSOR SUPPLY

page –

Description: Battery voltage to sensor. 000098

DIAG CAN/POWER 13(20) 797-O FRAME 24V SENSOR SUPPLY XY 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

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.

790-O FRAME, 5V REF

page –

Description: not connected Circuit diagram: 000098

DIAG CAN/POWER 13(20) 797-O FRAME 24V SENSOR SUPPLY XY 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)

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6

Le X Ri X

000099

Connection:

RED.POWER

Le: redundant feed to D790/K1:8 Ri: redundant feed to D790/K1:7 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

Workshop manual DRF 400–450

VDRF03.02GB

34

8 Control system – 8.4.1.15 CAN/POWER, menu 15

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

DIAG CAN/POWER 15(20) 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) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

793 TRANSMISSION, IGNITION POWER

page –

Description: Ignition voltage (15) to transmission control unit (D793). Circuit diagram: Circuit Power group 11.5, Circuit Dana TE 32000 group 2.0, Circuit Dana TE 32000FF group 2.0 000100

DIAG CAN/POWER 15(20) 793 TRANSMISSION POWER XX.XXV IGNITION POWER XX.XXV SENSOR SUPPLY XX.XXV

Connection: 15-voltage from K315/87 via F54/4 and F58-2/5 to D793/ S2 Function: 11.5.1.3 Ignition voltage (15) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

793 TRANSMISSION, SENSOR SUPPLY

page –

Description: voltage feed to sensors on transmission, reference voltage of 5 V. Circuit diagram: Circuit Dana TE 32000 group 2.0, Circuit Dana TE 32000FF group 2.0 000100

DIAG CAN/POWER 15(20) 793 TRANSMISSION POWER XX.XXV IGNITION POWER XX.XXV SENSOR SUPPLY 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). Circuit diagram: Circuit Power group 11.5 00003179

DIAG CAN/POWER 16(20) 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 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.1.17 CAN/POWER, menu 17

35

791-1 ATTACHMENT, RED. POWER

page –

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

00003179

DIAG CAN/POWER 16(20) 791-1 ATTACHMENT POWER XX.XXV RED.POWER Le X Ri X

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit CAN BUS ATT group, 11.6 Connection: Le: redundant voltage feed to D791/K2:7 Ri: redundant voltage feed to D791/K2:8 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

8.4.1.17

CAN/POWER, menu 17

791-2 ATTACHMENT, POWER

page –

Description: Battery voltage to Control unit, attachment option (D791-2). 000102

DIAG CAN/POWER 17(20) 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 Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 and F52-1 to D791-2/K2:1, K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

791-2 ATTACHMENT, RED. POWER

page –

Description: Redundant voltage to Control unit, attachment option (D791-2). 000102

DIAG CAN/POWER 17(20) 791-2 ATTACHMENT POWER XX.XXV RED.POWER Le X Ri X

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit CAN BUS ATT group, 11.6 Connection: Le: redundant feed to D791-2/K2:7 Ri: redundant feed to D791-2/K2:8 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

Workshop manual DRF 400–450

VDRF03.02GB

36

8 Control system – 8.4.1.18 CAN/POWER, menu 18

8.4.1.18

CAN/POWER, menu 18

791-3 ATTACHMENT, POWER

page –

Description: Battery voltage to Control unit, attachment left jack pair (D791-3). 000103

DIAG CAN/POWER 18(20) 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 Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 and F52-2 to D791-3/K2:1, K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30V (battery voltage).

791-3 ATTACHMENT, RED. POWER

page –

Description: Redundant voltage to Control unit, attachment left jack pair (D791-3). 000103

DIAG CAN/POWER 18(20) 791-3 ATTACHMENT POWER XX.XXV RED.POWER Le X Ri X

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit CAN BUS ATT group, 11.6 Connection: Le: redundant feed to D791-3/K2:7 Ri: redundant feed to D791-3/K2:8 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

8.4.1.19

CAN/POWER, menu 19

791-4 ATTACHMENT, POWER

page –

Description: Battery voltage to Control unit, attachment right jack pair (D791-4). 000104

DIAG CAN/POWER 19(20) 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 Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 and F52-2 to D791-4/K2:1, K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30V (battery voltage).

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.1.20 CAN/POWER, menu 20

37

791-4 ATTACHMENT, RED. POWER

page –

Description: Redundant voltage to Control unit, attachment right jack pair (D791-4). 000104

DIAG CAN/POWER 19(20) 791-4 ATTACHMENT POWER XX.XXV RED.POWER Le X Ri X

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit CAN BUS ATT group, 11.6 Connection: Le: redundant feed to D791-4/K2:7 Ri: redundant feed to D791-4/K2:8 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

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

DIAG CAN/POWER 20(20) 24V SENS.SUP 791-1 XY 24V SENS.SUP 791-2 XY 24V SENS.SUP 791-3 XY 24V SENS.SUP 791-4 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

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.

Workshop manual DRF 400–450

VDRF03.02GB

38

8 Control system – 8.4.1.20 CAN/POWER, menu 20

24V SENS. SUP 791-2

page –

Description: Voltage feed to position sensors connected to Control unit, attachment (D791-2). 003180

DIAG CAN/POWER 20(20) 24V SENS.SUP 791-1 XY 24V SENS.SUP 791-2 XY 24V SENS.SUP 791-3 XY 24V SENS.SUP 791-4 XY

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

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.

24V SENS. SUP 791-3

page –

Description: Battery voltage to position sensor for left jack pair on combi attachment. 003180

DIAG CAN/POWER 20(20) 24V SENS.SUP 791-1 XY 24V SENS.SUP 791-2 XY 24V SENS.SUP 791-3 XY 24V SENS.SUP 791-4 XY

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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.1.21 CAN/POWER, menu 21

39

24V SENS. SUP 791-4

page –

Description: Battery voltage to position sensor for right jack pair on combi attachment. 003180

DIAG CAN/POWER 20(20) 24V SENS.SUP 791-1 XY 24V SENS.SUP 791-2 XY 24V SENS.SUP 791-3 XY 24V SENS.SUP 791-4 XY

Circuit diagram: Circuit Combi Att group 7.9 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

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.

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

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6 CAN R

D791-3 CAN R

CAN L

CAN L

4 5

CAN R

D791-1

CAN L

3

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

2

8

0

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.

Workshop manual DRF 400–450

VDRF03.02GB

40

8 Control system – 8.4.2 LIGHTS

8.4.2

LIGHTS

LIGHTS, description

page –

This group covers lighting. Confirm selection with function key for Enter.

012083

DIAGNOSIS CAN/POWER LIGHTS CAB 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

Input signal active.

0

No signal.

WORKING LIGHT CAB, OUTPUT

page –

Description: Voltage feed to working lights cab roof. Circuit diagram: Working lights group 9.6 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

VDRF03.02GB

Workshop manual DRF 400–450

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. Circuit diagram: Working lights group 9.6 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

Function: 9.6 Lighting system Signal value: 1

Input signal active.

0

No signal.

WORKING LIGHT ATTACH, OUTPUT

page –

Description: Voltage feed to working light, attachment, feed. Circuit diagram: Working lights group 9.6 Connection: LE: digital out from D791/K1:15 to E404-2L

012084

DIAG LIGHTS 2(13) WORKING LIGHT ATTACH 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

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.

Workshop manual DRF 400–450

VDRF03.02GB

42

8 Control system – 8.4.2.3 LIGHTS, menu 3

WORKING LIGHT ATTACH, OPT OUTPUT (2X)

page –

Description: Voltage feed to the extra working lights on the attachment. 012084

DIAG LIGHTS 2(13) WORKING LIGHT ATTACH 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

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.

8.4.2.3

LIGHTS, menu 3

WORKING LIGHT BOOM, SWITCH

page –

Description: Signal from switch working light boom.

VDRF03.02GB

Circuit diagram: Working lights group 9.6 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

Function: 9.6 Lighting system Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.2.3 LIGHTS, menu 3

43

WORKING LIGHT BOOM, OUTPUT

page –

Description: Voltage feed to working light boom. Circuit diagram: Working lights group 9.6 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

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.

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

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.

Workshop manual DRF 400–450

VDRF03.02GB

44

8 Control system – 8.4.2.4 LIGHTS, menu 4

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

X

Connection: from S100/1 to digital in D790-1/K6:5 000110

DIAG LIGHTS MAIN LIGHT SWITCH

Function: 9.6 Lighting system Signal value: 1

Input signal active.

0

No signal.

8.4.2.5

LIGHTS, menu 5

PRESENT OUTPUT SIGNAL, SIDE F

page –

Description: Voltage feed to side lights front. Circuit diagram: Circuit Lighting group 9.6 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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.2.5 LIGHTS, menu 5

45

PRESENT OUTPUT SIGNAL, SIDE R

page –

Description: Voltage feed to side lights rear. Circuit diagram: Circuit Lighting group 9.6 Connection: LE: digital out from D797-R/K1:7 to H416-2

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-R/K1:9 to H417-2 Function: 9.6.2 Running lights 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.

PRESENT OUTPUT SIGNAL, REAR

page –

Description: Voltage feed to rear lights. Circuit diagram: Circuit Lighting group 9.6 Connection: LE: digital out from D797-R/K1:10 to H412L

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-R/K1:25 to H412R Function: 9.6.3 Rear lights 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.

Workshop manual DRF 400–450

VDRF03.02GB

46

8 Control system – 8.4.2.6 LIGHTS, menu 6

8.4.2.6

LIGHTS, menu 6

HEADLIGHTS, SWITCH

page –

Description: Lighting headlights front, switch. Circuit diagram: Circuit Lighting group 9.6 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

Function: 9.6 Lighting system Signal value: 1

Input signal active.

0

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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.2.7 LIGHTS, menu 7

47

HEAD LIGHTS, DIMMED

page –

Description: Voltage feed to headlights, low beams. Circuit diagram: Circuit Lighting group 9.6 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

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.

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) PRESENT INPUT SIGNAL HAZARD SWITCH X FLASH.SW. LE X RI X

Connection: from S109/1 to digital in D790-1/K5:6 Function: 9.7 Signalling system Signal value: 1

Input signal active.

0

No signal.

PRESENT INPUT SIGNAL, FLASH.SW.

page –

Description: Signal from switch direction indicators. Circuit diagram: Circuit Direction indicators, Hazard flashers, group 9.7 000113

DIAG LIGHTS 7(13) PRESENT INPUT SIGNAL 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 Function: 9.6 Lighting system Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

48

8 Control system – 8.4.2.8 LIGHTS, menu 8

8.4.2.8

LIGHTS, menu 8

PRESENT OUTPUT SIGNAL HAZARD/FLASHER, FRONT

page –

Description: Voltage feed to direction indicators front. Circuit diagram: Circuit Direction indicators, Hazard flashers, group 9.7 000114

DIAG LIGHTS 8(13) PRESENT OUTPUT SIGNAL 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

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.

PRESENT OUTPUT SIGNAL HAZARD/FLASHER, REAR

page –

Description: Voltage feed to direction indicators rear. Circuit diagram: Circuit Direction indicators, Hazard flashers, group 9.7 000114

DIAG LIGHTS 8(13) PRESENT OUTPUT SIGNAL 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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.2.9 LIGHTS, menu 9

8.4.2.9

49

LIGHTS, menu 9

ROTATING BEACON, SWITCH

page –

Description: Signal from switch rotating beacon.

9(13) X XY

Circuit diagram: Circuit Lighting group 9.6 Connection: from S110/1 to digital in D790-1/K6:4 000115

DIAG LIGHTS ROTATION BEACON SWITCH OUTPUT

Function: 9.6 Lighting system Signal value: 1

Input signal active.

0

No signal.

ROTATING BEACON, OUTPUT

page –

Description: Voltage feed to rotating beacon.

9(13) X XY

Circuit diagram: Circuit Lighting group 9.6 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

8.4.2.10

LIGHTS, menu 10

PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH

page –

Description: Signal from make-contact brake lights. Circuit diagram: Circuit Lighting group 9.6 Connection: from S216/2 to digital in D797-F/K1:13 013260

DIAG LIGHTS 10(13) PRESENT INPUT SIGNAL BRAKE LIGHT SWITCH X REVERSE LIGHT SIGNAL X

Function: 4.3.8 Make-contact brake lights Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

50

8 Control system – 8.4.2.11 LIGHTS, menu 11

PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL

page –

Description: Signal from transmission control unit (D793) when reverse gear is activated. Circuit diagram: Circuit Lighting group 9.6 013260

DIAG LIGHTS 10(13) PRESENT INPUT SIGNAL 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).

0

No signal.

8.4.2.11

LIGHTS, menu 11

PRESENT OUTPUT SIGNAL, BRAKE LIGHT

page –

Description: Voltage feed to brake lights. Circuit diagram: Circuit Lighting group 9.6 Connection: LE: digital out from D797-R/K1:32 to H411L

000117

DIAG LIGHTS 11(13) PRESENT OUTPUT SIGNAL BRAKE LIGHT LEXY RIXY REVERSE LGT LEXY RIXY REVERSE ALARM XY

RI: digital out from D797-R/K1:33 to H411R Function: 9.6.4 Brake lights 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.2.11 LIGHTS, menu 11

51

PRESENT OUTPUT SIGNAL, REVERSE LGT

page –

Description: Voltage feed to brake lights. Circuit diagram: Circuit Lighting group 9.6 Connection: LE: digital out from D797-R/K1:28 to H405L

000117

DIAG LIGHTS 11(13) PRESENT OUTPUT SIGNAL BRAKE LIGHT LEXY RIXY REVERSE LGT LEXY RIXY REVERSE ALARM XY

RI: digital out from D797-R/K1:42 to H405R Function: 9.6.5 Back-up light 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.

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) PRESENT OUTPUT SIGNAL BRAKE LIGHT LEXY RIXY REVERSE LGT LEXY RIXY REVERSE ALARM XY

Function: 9.7.5 Back-up alarm 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.

Workshop manual DRF 400–450

VDRF03.02GB

52

8 Control system – 8.4.2.12 LIGHTS, menu 12

8.4.2.12

LIGHTS, menu 12

CAB LIGHT, MANUAL SWITCH

page –

Description: Signal from switch lighting cab.

12(13) X X XXX

Circuit diagram: Circuit Lighting group 9.6 Connection: from KIT, D790-2/K8:11 to digital in D790-1/K11:2 000118

DIAG LIGHTS CAB LIGHT MANUAL SWITCH DOOR SWITCH OUTPUT

Function: 9.6 Lighting system Signal value: 1

Input signal active.

0

No signal.

CAB LIGHT, DOOR SWITCH

page –

Description: Signal from contact breaking door.

12(13) X X XXX

Circuit diagram: Circuit Lighting group 9.6

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

Input signal active.

0

No signal.

CAB LIGHT, OUTPUT

page –

Description: Voltage feed to interior light cab.

12(13) X X XXX

Circuit diagram: Circuit Sensor instr. group 9.1 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.

Workshop manual DRF 400–450

8 Control system – 8.4.3 CAB

8.4.3

53

CAB

CAB, description

page –

This group covers functions in the cab. Confirm selection with function key for Enter.

012086

DIAGNOSIS CAN/POWER LIGHTS CAB 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

Input signal active.

0

No signal.

WASHER, OUTPUT

page –

Description: Voltage feed to windscreen washer motor.

1(X) X XY XY

Circuit diagram: Circuit Wipers group 9.5 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

Workshop manual DRF 400–450

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

Circuit diagram: Circuit Wipers group 9.5 Connection: PWM out D790-1/K5:4 to M651-2 Function: 9.5.4 Washer motor and reservoir 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.

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

Circuit diagram: Circuit Wipers group 9.5 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 Function: 9.5 Wiping and cleaning of windows Signal value:

VDRF03.02GB

1

Long interval.

2

Normal interval.

3

Continuous operation.

Workshop manual DRF 400–450

8 Control system – 8.4.3.3 CAB, menu 3

55

FRONT WIPER, OUTPUT

page –

Description: Voltage feed to wiper front.

2(10) X XY X

Circuit diagram: Circuit Wipers group 9.5 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

FRONT WIPER, FEEDBACK

page –

Description: Signal from motor wiper front, indicates when wiper motion is completed.

2(10) X XY X

Circuit diagram: Circuit Wipers group 9.5 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).

0

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

Circuit diagram: 000123

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.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

56

8 Control system – 8.4.3.4 CAB, menu 4

REAR WIPER, OUTPUT

page –

Description: Voltage feed to direction windscreen wiper rear.

3(10) X XY X

Circuit diagram: Circuit Wipers group 9.5 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

REAR WIPER, FEEDBACK

page –

Description: Signal from motor windscreen wiper rear, indicates when wiper motion is completed.

3(10) X XY X

Circuit diagram: Circuit Wipers group 9.5 000123

DIAG CAB REAR WIPER SWITCH OUTPUT FEEDBACK

Connection: from M650-2/31b to digital in D790-1/K12:2 Function: 9.5.7 Wiper motor rear Signal value: 1

Input signal active (wiper sweep).

0

No signal (home position).

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

Function: 9.5 Wiping and cleaning of windows Signal value: 1

Input signal active. Key for continuous/interval pressed down.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.3.5 CAB, menu 5

57

ROOF WIPER, OUTPUT

page –

Description: Voltage feed to wiper roof.

4(10) X XY X

Circuit diagram: Circuit Wipers group 9.5 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

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.

ROOF WIPER, FEEDBACK

page –

Description: Signal from motor wiper roof, indicates when wiper motion is completed.

4(10) X XY X

Circuit diagram: Circuit Wipers group 9.5 000124

DIAG CAB ROOF WIPER SWITCH OUTPUT FEEDBACK

Connection: from M650-3/31b to digital in D790-1/K12:4 Function: 9.5.6 Wiper motor roof Signal value: 1

Input signal active (wiper sweep).

0

No signal (home position).

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

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

58

8 Control system – 8.4.3.5 CAB, menu 5

HORN, OUTPUT

page –

Description: Voltage feed to horn.

5(10) X XY X

Circuit diagram: Circuit Alarm, audible signals group 9.7

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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

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

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.3.6 CAB, menu 6

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

Circuit diagram: Circuit Alarm, audible signals group 9.7 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

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.

SWITCH SEAT

page –

Description: Signal from sensor operator in seat.

6(10) XY X X X

Circuit diagram: Circuit Alarm, audible signals group 9.7 Connection: signal from S230/1 to D790-1/K11:14 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.

0

No signal. No operator in seat.

ALARM

page –

6(10) XY X X X

Description: Status for alarm indication panel, warning from control system. Circuit diagram: 000126

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

0

Conditions for activation of buzzer are not fulfilled.

Workshop manual DRF 400–450

VDRF03.02GB

60

8 Control system – 8.4.3.7 CAB, menu 7

OP

page –

Description: Status for overload warning from the control system.

6(10) XY X X X

Circuit diagram: Circuit OP + Scale group 8.2 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.

0

Conditions for activation of buzzer are not fulfilled.

8.4.3.7

CAB, menu 7

FUEL, SENSOR VALUE

page –

Description: Signal from sensor fuel level.

7(10) XXXOHM XXX

Circuit diagram: Circuit Sensor instr. group 9.1

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 system’s interpretation of signal from fuel tank sensor.

7(10) XXXOHM XXX

Circuit diagram: Circuit Sensor instr. group 9.1 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 driver’s seat group 9.3 000128

DIAG CAB SEAT HEATER SWITCH OUTPUT

Connection: signal from S143/1 to digital in D790-1/K6:6 Function: 9.3 Seat Signal value:

VDRF03.02GB

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.3.9 CAB, menu 9

61

SEAT HEATER, OUTPUT

page –

8(10) Description: Control voltage to seat heating relay.

X XY

Circuit diagram: Circuit Cab driver’s 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

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.

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

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.

Workshop manual DRF 400–450

VDRF03.02GB

62

8 Control system – 8.4.3.10 CAB, menu 10

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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

8.4.4

CLIMATE

CLIMATE, description

page –

This group covers the cab’s climate control system. Confirm selection with function key for Enter.

012088

DIAGNOSIS CAN/POWER LIGHTS CAB 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.

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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) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX

Function: 9.4 Heating, ventilation and air conditioning Signal value: XXX = 160-280 = 16-28 °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.

Workshop manual DRF 400–450

8 Control system – 8.4.4.2 CLIMATE, menu 2

63

PRESENT INPUT SIGNAL, PRESENT TEMP

page –

Description: Signal from sensor cab temperature. Circuit diagram: Circuit Climate system group 9.4 Connection: signal from B775-1/2 to input D790-1/K4:8 000132

DIAG CLIMATE 1(8) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX

Function: 9.4.17 Sensor cab temperature Signal value: XXX = Cab’s interior temperature in tenths of degrees (200 = 20 °C).

PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

page –

Description: Water valve’s position (opening in percent). Circuit diagram: Circuit Climate system group 9.4 Connection: signal from Y673/9 to analogue in D790-1/K10:4 000132

DIAG CLIMATE 1(8) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX

Function: 9.4.5 Water valve Signal value: XXX = 0-100 = 0-100% = Water valve’s opening in %. 0 = Closed. 100 = Fully open.

8.4.4.2

CLIMATE, menu 2

TEMP COIL

page –

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. Circuit diagram: Circuit Climate system group 9.4 000133

DIAG TEMP TEMP TEMP TEMP

Connection: signal from B775-2/2 to input D790-1/K4:10 Function: 9.4.16 Sensor temperature outlet fan Signal value: XXX = Temperature of the air blown into the cab in tenths of degrees (200 = 20 °C).

TEMP COOLANT

page –

CLIMATE COIL COOLANT AMBIENT DE-ICE

2(8) XXX XXX XXX XXX

Description: Coolant temperature, temperature of the engine’s coolant. Signal is retrieved from the engine via CAN bus drivetrain. Circuit diagram: Circuit Climate system group 9.4 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. Circuit diagram: Circuit Climate system group 9.4 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).

Workshop manual DRF 400–450

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64

8 Control system – 8.4.4.3 CLIMATE, menu 3

TEMP DE-ICE

page –

Description: Temperature in refrigerant circuit.

CLIMATE COIL COOLANT AMBIENT DE-ICE

2(8) XXX XXX XXX XXX

Circuit diagram: Circuit Climate system group 9.4 Connection: signal from B775-3/2 to input D790-1/K4:11 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. Circuit diagram: Circuit Climate system group 9.4 Connection: signal from S246/2 to digital in D797-R/K1:37 Function: 9.4.10 Pressure switch

006865

DIAG CLIMATE 3(X) PRESENT INPUT SIGNAL PRESSURE SWITCH X OPT DOOR SWITCH X

Signal value: 1

Input signal active. Press Ok.

0

No signal, too high or too low pressure.

PRESENT INPUT SIGNAL, OPT DOOR SWITCH

page –

Description: Signal from the driver’s 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) PRESENT INPUT SIGNAL PRESSURE SWITCH X OPT DOOR SWITCH X

Circuit diagram: Circuit Lighting group 9.6 Connection: signal from S266-LE or S266-RI to digital in D790-1/ K11:3 Function: 9.10.2 Doors Signal value: 1

Input signal active. Door open.

0

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. Circuit diagram: Circuit Climate system group 9.4 000135

DIAG CLIMATE 4(8) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV

Connection: signal from Y673/9 to analogue in D790-1/K10:4 Function: 9.4.5 Water valve Signal value: XX.XXV = 0.50 - 4.50 V

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.4.5 CLIMATE, menu 5

65

PRESENT INPUT SIGNAL, DRAUGHT VALVE

page –

Description: Signal from the engine to the air distributor. Voltage is a measure of the valve’s position. Circuit diagram: Circuit Climate system group 9.4 000135

DIAG CLIMATE 4(8) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV

Connection: signal from Y672/9 to analogue in D790-1/K4:7 Function: 9.4.14 Air distributor Signal value: XX.XXV = 0.50 - 4.50 V

8.4.4.5

CLIMATE, menu 5

PRESENT INPUT SIGNAL, REQUIRED TEMP

page –

Description: Signal from switch temperature. Voltage when switch is pressed in voltage level indicates increase or decrease of the temperature. Circuit diagram: Circuit Climate system group 9.4 000136

DIAG CLIMATE 5(8) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED XX.XXV

Connection: signal from S139/3 to analogue in D790-1/K5:8 Function: 9.4 Heating, ventilation and air conditioning Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.

PRESENT INPUT SIGNAL, REQ. DRAUGHT

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 valve’s position changes in steps between windscreen - floor. 000136

DIAG CLIMATE 5(8) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED XX.XXV

Circuit diagram: Circuit Climate system group 9.4 Connection: signal from S117/3 to analogue in D790-1/K5:9 Function: 9.4 Heating, ventilation and air conditioning Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Up / - / down.

PRESENT INPUT SIGNAL, FAN SPEED

page –

Description: Signal from switch fan speed, switch controls increase or decrease of fan speed. Speed is endless adjustable. The voltage level indicates if the speed should be increased or decreased. Circuit diagram: Circuit Climate system group 9.4 000136

DIAG CLIMATE 5(8) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED XX.XXV

Connection: signal from S118/2 to analogue in D790-1/K5:7 Function: 9.4 Heating, ventilation and climate control unit Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.

Workshop manual DRF 400–450

VDRF03.02GB

66

8 Control system – 8.4.4.6 CLIMATE, menu 6

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). Circuit diagram: Circuit Climate system group 9.4 000137

DIAG CLIMATE 6(8) PRESENT OUTPUT SIGNAL FAN SPEED XXX RECIRKULATION XY COMPRESSOR XY

Connection: analogue out from D790-1/K2:2 to M657/31 Function: 9.4.3 cab fan Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).

PRESENT OUTPUT SIGNAL, RECIRCULATION

page –

Description: Control voltage to motor for fresh air and recirculation damper. Circuit diagram: Circuit Climate system group 9.4 000137

DIAG CLIMATE 6(8) PRESENT OUTPUT SIGNAL 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

PRESENT OUTPUT SIGNAL, COMPRESSOR

page –

Description: Voltage feed of AC compressor’s electromagnetic clutch. Controls cut-in and cut-out of the compressor. Two outputs are connected in parallel to handle the current. Circuit diagram: Circuit Climate system group 9.4 000137

DIAG CLIMATE 6(8) PRESENT OUTPUT SIGNAL 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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.4.7 CLIMATE, menu 7

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 valve’s position changes. The valve’s opening and closing is controlled by the climate control unit’s software depending on desired temperature, outside temp. cab temperature and coolant temperature, so it may be difficult to determine whether the valve is working as it should.

DIAG CLIMATE 7(8) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY

24V

Circuit diagram: Circuit Climate system group 9.4 Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from D790-1/K4:2 via R4 to Y673/6 Function: 9.4.5 Water valve

M

000138

0V

Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11 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.

H-bridge 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.

Workshop manual DRF 400–450

VDRF03.02GB

68

8 Control system – 8.4.4.8 CLIMATE, menu 8

OUTPUT WATER VALVE, COUNTER-CLOCKWISE

page –

Description: Voltage feed to water valve, for closing. The valve is connected to an H-bridge. The signal can only be diagnosed when the valve’s position changes. The valve’s opening and closing is controlled by the climate control unit’s software depending on desired temperature, outside temp. cab temperature and coolant temperature, so it may be difficult to determine whether the valve is working as it should.

DIAG CLIMATE 7(8) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY

24V

Circuit diagram: Circuit Climate system group 9.4 Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from D790-1/K4:2 via R4 to Y673/6 Function: 9.4.5 Water valve

M

000138

Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11

0V

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.

H-bridge 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.

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 distributor’s position changes.

DIAG CLIMATE 8(8) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY

Circuit diagram: Circuit Climate system group 9.4 Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from D790-1/K4:4 via R6 to Y672/6

24V

Function: 9.4.14 Air distributor Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11

M

00

No output signal and open circuit in the circuit.

01

Normal mode function off.

0V

H-bridge

VDRF03.02GB

000139

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.

Workshop manual DRF 400–450

8 Control system – 8.4.4.8 CLIMATE, menu 8

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 distributor’s position changes.

DIAG CLIMATE 8(8) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY

Circuit diagram: Circuit Climate system group 9.4 Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from D790-1/K4:4 via R6 to Y672/6

24V

Function: 9.4.14 Air distributor Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11

M

00

No output signal and open circuit in the circuit.

01

Normal mode function off.

0V

H-bridge

000139

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.

Workshop manual DRF 400–450

VDRF03.02GB

70

8 Control system – 8.4.5 HYD

8.4.5

HYD

HYD, description

page –

This group covers the hydraulic functions. Confirm selection with function key for Enter.

009272

DIAGNOSIS CAN/POWER LIGHTS CAB 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

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).

Workshop manual DRF 400–450

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. Circuit diagram: Circuit Brake system group 4.0 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

Normal mode function off. 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

Normal mode function on. Output signal active, circuit OK.

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. Circuit diagram: Circuit OP + Scale group 8.2 Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C- page 134 Function: 8.2.1 Overload system

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+

Workshop manual DRF 400–450

VDRF03.02GB

72

8 Control system – 8.4.5.4 HYD, menu 4

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

.

Circuit diagram: Circuit OP + Scale group 8.2 Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C+ page 134 Function: 8.2.1 Overload system 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. Circuit diagram: Circuit Brake system group 4.0 Connection: signal from S204/2 to analogue in D797-F/K1:20 012403

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

Function: 4.3.7 NC switch oil pressure, brake system Signal value: 1

Input signal active.

0

No signal.

PRESSURE SWITCHES, BRAKE LIGHT PRESS.

page –

Description: Signal from make-contact brake lights.

VDRF03.02GB

Circuit diagram: Circuit Lighting group 9.6 Connection: from S216/2 to analogue in D797-F/K1:13 012403

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

Function: 4.3.8 Make-contact brake lights Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.5.5 HYD, menu 5

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 BRAKE LIGHT PRESS. X DECLUTCH PRESSURE X

Function: 2.8.2 NO switch, declutch Signal value: 1

Input signal active.

0

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

Circuit diagram: Circuit Brake system group 4.0 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

Circuit diagram: Circuit Brake system group 4.0 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

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

74

8 Control system – 8.4.5.6 HYD, menu 6

P-BRAKE, VALVE

page –

Description: Voltage feed to Solenoid valve parking brake.

5(X) X/Y X XY

Circuit diagram: Circuit Brake system group 4.0 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

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.

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) PRESENT OUTPUT SIGNAL 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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.6 ENGINE

8.4.6

75

ENGINE

ENGINE, description

page –

This group covers engine functions. Confirm selection with function key for Enter.

012093

DIAGNOSIS CAN/POWER LIGHTS CAB 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. Circuit diagram: Circuit Drivetrain group 1.1 Connection: signal from R690/2 to analogue in D790-1/K6:11 Function: 1 Engine

006866

DIAG ENGINE 1(X) PRESENT INPUT SIGNAL 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. Circuit diagram: 006866

DIAG ENGINE 1(X) PRESENT INPUT SIGNAL ACCELERATOR X.XXV REQUIRED SPD PROC XXX REQUIRED SPD RPM XXXX

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. Circuit diagram: 006866

DIAG ENGINE 1(X) PRESENT INPUT SIGNAL ACCELERATOR X.XXV REQUIRED SPD PROC XXX REQUIRED SPD RPM XXXX

Connection: Function: 1.9 Control system, engine Signal value: XXXX = 0-2010 rpm

8.4.6.2

ENGINE, menu 2

PRESENT INPUT SIGNAL, ENGINE SPEED EDC

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. Circuit diagram: 009281

DIAG ENGINE 2(X) PRESENT INPUT SIGNAL ENGINE SPEED EDC XXXX ENGINE SPEED TCU XXXX

Connection: Function: 1.9.2 Sensor engine rpm Signal value: XXXX = Active speed in rpm.

Workshop manual DRF 400–450

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. Circuit diagram: 009281

DIAG ENGINE 2(X) PRESENT INPUT SIGNAL 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 engine’s capacity. Circuit diagram: 006867

DIAG ENGINE 3(X) PRESENT INPUT SIGNAL PRESENT TORQUE XXX PRESENT TORQUE XXX PRES TORQUE @ RPM XXX

Connection: Function: 1.9 Control system, engine 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). Circuit diagram: 006867

DIAG ENGINE 3(X) PRESENT INPUT SIGNAL PRESENT TORQUE XXX PRESENT TORQUE XXX PRES TORQUE @ RPM XXX

Connection: Function: 1.9 Control system, engine Signal value: XXX = 0-100%

PRESENT INPUT SIGNAL, PRES TORQUE @ RPM

page –

Description: Available torque at current engine speed.

VDRF03.02GB

Circuit diagram: Connection: 006867

DIAG ENGINE 3(X) PRESENT INPUT SIGNAL PRESENT TORQUE XXX PRESENT TORQUE XXX PRES TORQUE @ RPM XXX

Function: 1.9 Control system, engine Signal value: XXX = 0-100%

Workshop manual DRF 400–450

8 Control system – 8.4.6.4 ENGINE, menu 4

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) PRESENT INPUT SIGNAL PREHEAT SWITCH X CRANK ENGINE SWITCH X D+ X

Circuit diagram: Circuit Power group 11.5 Connection: signal from S150/19 to digital in D790-2/K2:2 Function: 1 Engine, 1.10.1 Preheating Signal value: 1

Input signal active.

0

No signal.

PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

page –

Description: Signal from ignition, start position. Circuit diagram: Circuit Power group 11.5 Connection: signal from S150/50 to digital in D790-2/K2:1 009282

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

Function: 1.1.1 Engine, 1.11 Start and stop Signal value: 1

Input signal active.

0

No signal.

PRESENT INPUT SIGNAL, D+

page –

Description: Signal from alternator, indicates if alternator supplies current. Circuit diagram: Circuit Power group 11.5 009282

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

Connection: from G660/D+ to digital in D797-R/K2:16 Function: 11.4.1 Alternator Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

78

8 Control system – 8.4.6.5 ENGINE, menu 5

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) PRESENT OUTPUT SIGNAL PREHEAT X CRANK ENGINE X

Cummins: controlled by engine’s control system. Function: 1.10.1 Preheating Signal value: 1

Output signal active.

0

No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE

page –

Description: Status for Voltage feed starter motor. Circuit diagram: Circuit Power group 11.5 Connection: Volvo: software signals on CAN-bus drivetrain

000152

DIAG ENGINE 5(10) PRESENT OUTPUT SIGNAL PREHEAT X CRANK ENGINE X

Cummins: digital out D797-R/K1:36 to K360/86 Function: 1.11 Start and stop 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.6.6 ENGINE, menu 6

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) PRESENT INPUT SIGNAL 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) PRESENT INPUT SIGNAL 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) PRESENT INPUT SIGNAL 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.

Workshop manual DRF 400–450

VDRF03.02GB

80

8 Control system – 8.4.6.7 ENGINE, menu 7

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). Circuit diagram: see supplier documentation, engine 009284

DIAG ENGINE 7(X) PRESENT INPUT SIGNAL 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 control unit (D794) to cab control unit (D790-1). Circuit diagram: see supplier documentation, engine 009284

DIAG ENGINE 7(X) PRESENT INPUT SIGNAL OIL TEMP XXX COOLANT TEMP XXX INTAKE MAIN.TEMP XXX

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 Signal value: XXX = 200 equals 20 °C.

PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

page –

Description: Charge air temperature. CAN bus message from engine control unit (D794) to cab control unit (D790-1). Circuit diagram: see supplier documentation, engine 009284

DIAG ENGINE 7(X) PRESENT INPUT SIGNAL OIL TEMP XXX COOLANT TEMP XXX INTAKE MAIN.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 Signal value: XXX = 200 equals 20 °C.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.6.8 ENGINE, menu 8

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). Circuit diagram: 009279

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. Circuit diagram: 009279

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.

Workshop manual DRF 400–450

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8 Control system – 8.4.7 TRANSM

8.4.7

TRANSM

TRANSM, description

page –

This group covers the transmission function. Confirm selection with function key for Enter.

009274

DIAGNOSIS CAN/POWER LIGHTS CAB 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. Circuit diagram: Circuit Drivetrain group 2.1 000159

DIAG TRANSM. 1(15) PRESENT INPUT SIGNAL 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. Circuit diagram: Circuit Drivetrain group 2.1 Connection: signal from S220-1/2 to digital in D790-1/K6:14 000159

DIAG TRANSM. 1(15) PRESENT INPUT SIGNAL BRAKE PEDAL X.XXV DECLUTCH SWITCH X DECLUTCH PRESS SW. X

Function: 2.1.2 Declutch pedal Signal value: 1

Input signal active. Declutch pedal pressed down.

0

No signal.

PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

page –

Description: Signal from NO switch declutch (pressure switch).

VDRF03.02GB

Circuit diagram: Circuit Drivetrain group 2.1 Connection: signal from S220-2/2 to digital in D797-F/K1:41 000159

DIAG TRANSM. 1(15) PRESENT INPUT SIGNAL BRAKE PEDAL X.XXV DECLUTCH SWITCH X DECLUTCH PRESS SW. X

Function: 2.8.2 NO switch, declutch Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

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

Circuit diagram: Circuit Drivetrain group 2.1 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.

0

No signal.

SWITCHES, REVERSE

page –

Description: Signal from gear and multi-function lever (reverse).

2(15) X X X

Circuit diagram: Circuit Drivetrain group 2.1 Connection: from S162/R to digital in 790-2/K3:12 000160

DIAG TRANSM. SWITCHES FORWARD REVERSE SHIFT MODE

Function: 2 Transmission Signal value: 1

Input signal active. Travel direction reverse selected.

0

No signal.

SWITCHES, SHIFT MODE

page –

Description: Signal from shifting program switch. Status on CAN bus from KIT control unit (D790-2). The switches are integrated in the KIT control unit (D790-2).

2(15) X X X

Circuit diagram: 000160

DIAG TRANSM. SWITCHES FORWARD REVERSE SHIFT MODE

Connection: Function: 2 Transmission Signal value: 1

Shifting program 1 selected.

2

Shifting program 2 selected.

4

Automatic shifting selected.

Workshop manual DRF 400–450

VDRF03.02GB

84

8 Control system – 8.4.7.3 TRANSM, menu 3

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

Circuit diagram: 000161

DIAG TRANSM. PRESENT VALUE FORWARD REVERSE GEAR

Connection: Function: 2.8 Control system, transmission Signal value: 1

Output signal for travel direction forward active.

0

No output signal.

PRESENT VALUE, REVERSE

page –

Description: Status for rearward direction of travel from transmission control unit (D793). Indicates if rearward drive is activated in the transmission.

3(15) X X X

Circuit diagram: 000161

DIAG TRANSM. PRESENT VALUE FORWARD REVERSE GEAR

Connection: Function: 2.8 Control system, transmission Signal value: 1

Output signal for travel direction reverse active.

0

No output signal.

PRESENT VALUE, GEAR

page –

Description: Current gear, status from transmission control unit (D793). Shows which gear is activated in the transmission.

3(15) X X X

Circuit diagram: 000161

DIAG TRANSM. PRESENT VALUE FORWARD REVERSE GEAR

Function: 2.8 Control system, transmission Connection: Signal value: X = current gear.

8.4.7.4

TRANSM, menu 4

OPERATING STATE, AUT/MAN MODE

page –

Description: Shows which shifting program is selected automatic or manual.

4(15) X X X

Circuit diagram: 000162

DIAG TRANSM. OPERATING STATE AUT/MAN MODE WARNING OPERATING MODE

Connection: Function: 2.8 Control system, transmission Signal value:

VDRF03.02GB

1

Automatic.

0

Manual.

Workshop manual DRF 400–450

8 Control system – 8.4.7.5 TRANSM, menu 5

85

OPERATING STATE, WARNING

page –

Description: Warning for serious malfunction in transmission from transmission control unit (D793).

4(15) X X X

Circuit diagram: 000162

DIAG TRANSM. OPERATING STATE AUT/MAN MODE WARNING OPERATING MODE

Connection: Function: 2.8 Control system, transmission Signal value: 1

Active error.

0

No errors.

OPERATING STATE, OPERATING MODE

page –

Description: Operating mode status for transmission control unit (D793); also shown in control unit display.

4(15) X X X

Circuit diagram: 000162

DIAG TRANSM. OPERATING STATE AUT/MAN MODE WARNING OPERATING MODE

Connection: Function: 2.8 Control system, transmission Signal value: 0

Not used.

1

Manual or automatic shifting, standard mode shown during operation.

2

Not used.

3

Not used.

4

Limp-home, reduced capacity due to malfunction in transmission.

5

Shut-down, serious transmission malfunction control unit shuts down, likely that malfunction cannot be shown as CAN bus.

6

Calibration of transmission in progress.

8.4.7.5

TRANSM, menu 5

OPERATING STATE, SHIFT IN PROGRESS

page –

Description: Status for transmission function during operation, shifting in progress. Active during shifting. Circuit diagram: 000163

DIAG TRANSM. 5(15) OPERATING STATE SHIFT IN PROGRESS X FAULT X OLD FAULT X

Connection: Function: 2.8 Control system, transmission Signal value: 1

Shifting in progress.

0

No activity.

Workshop manual DRF 400–450

VDRF03.02GB

86

8 Control system – 8.4.7.6 TRANSM, menu 6

OPERATING STATE, FAULT

page –

Description: Status for transmission’s 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

Function: 2.8 Control system, transmission Signal value: 1

Active error code.

0

No error codes.

OPERATING STATE, OLD FAULT

page –

Description: Status for transmission’s function during operation, there are inactive error codes that have not been acknowledged. Circuit diagram: Connection: -

000163

DIAG TRANSM. 5(15) OPERATING STATE SHIFT IN PROGRESS X FAULT X OLD FAULT X

Function: 2.8 Control system, transmission Signal value: 1

There are inactive error codes that have not been acknowledged.

0

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

2

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.

3

4

000164

5

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

Workshop manual DRF 400–450

8 Control system – 8.4.7.6 TRANSM, menu 6

87

OUTPUT SPEED (transmission alternative Dana)

page –

DIAG TRANSM. DRUM SPEED OUTPUT SPEED ENGINE SPEED TURBINE SPEED 1

2

Description: Signal from sensor rpm output shaft (propeller shaft) (position 5).

6(15) XXXXHz XXXXHz XXXXHz XXXXHz

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from B758 till D793/ D3 and D793/ E3 Function: 2.3.9 Sensor rpm output shaft Signal value: XXXXHz = frequency, indicates pulses from the sensor in Hz (pulses /second). To convert to rpm, divide frequency by number of teeth on output shaft’s gear.

3

4

000164

5

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)

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

2

6(15) XXXXHz XXXXHz XXXXHz XXXXHz

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from B7558/766 to D793/H3 Function: 2.2.5 Sensor engine rpm and oil temperature transmission Signal value: XXXXHz = frequency, indicates pulses from the sensor in Hz (pulses /second). To convert to rpm, divide frequency by number of teeth on input shaft’s gear.

3

4

000164

5

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)

Workshop manual DRF 400–450

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8 Control system – 8.4.7.6 TRANSM, menu 6

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

2

6(15) XXXXHz XXXXHz XXXXHz XXXXHz

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from B751 to D793/R2 Function: 2.3.6 Sensor rpm turbine Signal value: XXXXHz = frequency, indicates pulses from the sensor in Hz (pulses /second). To convert to rpm, divide frequency by number of teeth on turbine’s gear.

3

4

000164

5

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)

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 Function: 2.2.5 Sensor engine rpm and oil temperature transmission Signal value: XXXXrpm = rotation speed.

1

2

3

6

013149

5 4 1. Sensor, drum rpm (B7520) 2.Temperature switch, torque converter (S2210) 3.Sensor, engine speed (B7530) 4.Sensor, turbine rpm transmission (B7510) 5.Sensor rpm output shaft (B7580) 6. Sensor temperature (B7660)

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.7.6 TRANSM, menu 6

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

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from B7510 to D793/G3 and D793/K3 Function: 2.3.6 Sensor rpm turbine Signal value: XXXXrpm = rotation speed.

1

2

3

6

013149

5 4 1. Sensor, drum rpm (B7520) 2.Temperature switch, torque converter (S2210) 3.Sensor, engine speed (B7530) 4.Sensor, turbine rpm transmission (B7510) 5.Sensor rpm output shaft (B7580) 6. Sensor temperature (B7660)

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

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from B7520 till D793/B3 and D793/C3 Function: 2.3.7 Sensor rpm drum Signal value: XXXXrpm = rotation speed.

1

2

3

6

013149

5 4 1. Sensor, drum rpm (B7520) 2.Temperature switch, torque converter (S2210) 3.Sensor, engine speed (B7530) 4.Sensor, turbine rpm transmission (B7510) 5.Sensor rpm output shaft (B7580) 6. Sensor temperature (B7660)

Workshop manual DRF 400–450

VDRF03.02GB

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8 Control system – 8.4.7.7 TRANSM, menu 7

OUTPUT SPEED (transmission alternative Dana full flow)

page –

DIAG TRANSM. ENGINE SPEED TURBINE SPEED DRUM SPEED OUTPUT SPEED 1

2

Description: Signal from sensor rpm output shaft (propeller shaft) (position 5).

6(15) XXXXrpm XXXXrpm XXXXrpm XXXXrpm

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from B7580 till D793/ D3 and D793/ E3 Function: 2.3.9 Sensor rpm output shaft Signal value: XXXXrpm = rotation speed.

3

6

013149

5 4 1. Sensor, drum rpm (B7520) 2.Temperature switch, torque converter (S2210) 3.Sensor, engine speed (B7530) 4.Sensor, turbine rpm transmission (B7510) 5.Sensor rpm output shaft (B7580) 6. Sensor temperature (B7660)

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. Circuit diagram: Circuit Dana TE 32000 group 2.0 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 Function: 2.8 Control system, transmission 11

Activated high and low side.

10

High side activated, low side no signal.

01

High side no signal, low side activated.

00

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.7.7 TRANSM, menu 7

91

OUTPUT STATUS, 2/4 VFS SELECTION (transmission alternative Dana)

page –

Description: Status of feed to solenoid valve VFS 2ND/4TH. Circuit diagram: Circuit Dana TE 32000 group 2.0 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

Function: 2.8 Control system, transmission Signal value: 1

Activated.

0

No signal.

OUTPUT STATUS, 1/3 VFS SELECTION (transmission alternative Dana)

page –

Description: Status of feed to solenoid valve VFS 1 ST/3 RD. Circuit diagram: Circuit Dana TE 32000 group 2.0 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

Function: 2.8 Control system, transmission Signal value: 1

Activated.

0

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

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from D793/K1 and D793/S3 to Y6066F 013178

DIAG TRANSM. FWD SELECTION REV SELECTION 2/4 SELECTION 1/3 SELECTION

Function: 2.8 Control system, transmission 1

Activated.

0

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

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from D793/E2 and D793/S3 to Y6066R 013178

DIAG TRANSM. FWD SELECTION REV SELECTION 2/4 SELECTION 1/3 SELECTION

Function: 2.8 Control system, transmission Signal value: 1

Activated.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

92

8 Control system – 8.4.7.8 TRANSM, menu 8

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

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from D793/K2 and D793/R2 to Y6074 Function: 2.8 Control system, transmission

013178

DIAG TRANSM. FWD SELECTION REV SELECTION 2/4 SELECTION 1/3 SELECTION

Signal value: 1

Activated.

0

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

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from D793/F2 and D793/S3 to Y60675 Function: 2.8 Control system, transmission

013178

DIAG TRANSM. FWD SELECTION REV SELECTION 2/4 SELECTION 1/3 SELECTION

Signal value: 1

Activated.

0

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

Circuit diagram: Circuit Dana TE 32000 group 2.0 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

1

Activated.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.7.8 TRANSM, menu 8

93

REV SUPPLY (transmission alternative Dana)

page –

Description: Status for control current to clutch pack reverse.

8(15) X X X X

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from D793/F1 to Y631 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: 1

Activated.

0

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

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from D793/E2 to Y6074 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: 1

Activated.

0

No signal.

1/3 SUPPLY (transmission alternative Dana)

page –

Description: Status for control current to clutch pack 1/3.

8(15) X X X X

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from D793/F2 to Y6075 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: 1

Activated.

0

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

Circuit diagram: Circuit Dana TE 32000FF group 2.0 013252

DIAG TRANSM. SUPPLY FWD/REV SUPPLY 2/4 SUPPLY 1/3 SUPPLY

Connection: digital out from D793/B1 and D793/C1 to Y6300 Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: 1

Activated.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

94

8 Control system – 8.4.7.9 TRANSM, menu 9

2/4 SUPPLY (transmission alternative Dana full flow)

page –

Description: Status for control current to clutch pack 2/4.

8(15) X X X

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: digital out from D793/F1 and D793/G1 to Y6069 013252

DIAG TRANSM. SUPPLY FWD/REV SUPPLY 2/4 SUPPLY 1/3 SUPPLY

Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: 1

Activated.

0

No signal.

1/3 SUPPLY (transmission alternative Dana full flow)

page –

Description: Status for control current to clutch pack 1/3.

8(15) X X X

Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: digital out from D793/ D1 and D793/ E1 to Y6067 013252

DIAG TRANSM. SUPPLY FWD/REV SUPPLY 2/4 SUPPLY 1/3 SUPPLY

Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: 1

Activated.

0

No signal.

8.4.7.9

TRANSM, menu 9

FWD FEEDBACK (transmission alternative Dana)

page –

9(X) XXXXmA XXXXmA XXXXmA XXXXmA

Description: Present control current to solenoid valve clutch pack forward. Circuit diagram: Circuit Dana TE 32000 group 2.0 006869

DIAG TRANSM. FWD FEEDBACK REV FEEDBACK 2/4 FEEDBACK 1/3 FEEDBACK

Connection: signal from D793/B1 to Y630 Function: 2.3.5 Valve block, transmission control, 2.8 Control system, 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 Circuit diagram: Circuit Dana TE 32000 group 2.0 006869

DIAG TRANSM. FWD FEEDBACK REV FEEDBACK 2/4 FEEDBACK 1/3 FEEDBACK

Connection: signal from D793/F1 to Y631 Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: XXXX = Measured value in mA.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.7.9 TRANSM, menu 9

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

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from D793/D1 to Y6069 006869

DIAG TRANSM. FWD FEEDBACK REV FEEDBACK 2/4 FEEDBACK 1/3 FEEDBACK

Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: XXXX = Measured value in mA.

1/3 FEEDBACK (transmission alternative Dana)

page –

Description: Present control current to solenoid valve clutch pack 1/3.

9(X) XXXXmA XXXXmA XXXXmA XXXXmA

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from D793/H1 to Y6067 006869

DIAG TRANSM. FWD FEEDBACK REV FEEDBACK 2/4 FEEDBACK 1/3 FEEDBACK

Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: XXXX = Measured value in mA.

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

Circuit diagram: Circuit Dana TE 32000FF group 2.0 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 Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: XXXX = Measured value in mA.

ANALOGUE OUTPUTS, 2/4 FEEDBACK (transmission alternative Dana full flow)

page –

Description: Present control current to solenoid valve clutch pack 2/4.

9(X) XXXXmA XXXXmA XXXXmA

Circuit diagram: Circuit Dana TE 32000FF group 2.0 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

Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: XXXX = Measured value in mA.

ANALOGUE OUTPUTS, 1/3 FEEDBACK (transmission alternative Dana full flow)

page –

Description: Present control current to solenoid valve clutch pack 1/3.

9(X) XXXXmA XXXXmA XXXXmA

Circuit diagram: Circuit Dana TE 32000FF group 2.0 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

Function: 2.3.5 Valve block, transmission control, 2.8 Control system, transmission Signal value: XXXX = Measured value in mA.

Workshop manual DRF 400–450

VDRF03.02GB

96

8 Control system – 8.4.7.10 TRANSM, menu 10

8.4.7.10

TRANSM, menu 10

PRESENT SENSOR INPUT, PRESS FEEDBACK (transmission alternative Dana)

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. Circuit diagram: Circuit Dana TE 32000 group 2.0 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

Circuit diagram: Circuit Dana TE 32000 group 2.0 Connection: signal from B758/766 to D793/H3 006870

DIAG TRANSM. PRESENT SENSOR PRESS FEEDBACK TRANSM.TEMP COOLER TEMP

Function: 2.7.2 Sensor engine rpm and oil temperature transmission 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. Circuit diagram: Circuit Dana TE 32000 group 2.0 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.

Workshop manual DRF 400–450

8 Control system – 8.4.7.10 TRANSM, menu 10

97

2/4 PRESSx10 (transmission alternative Dana full flow)

page –

10(X) XXXXBar XXXXBar XXXXmV XXXXmV

Description: Signal from oil pressure sensor in transmission. Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from B6069 to D793/S1 013410

DIAG TRANSM. 2/4 PRESSx10 1/3 PRESSx10 TRANSM.TEMP CONV OUT TEMP

Function: 2.6.2 Sensor oil pressure Signal value: 0-5 bar

Short-circuiting to ground.

8-15 bar

Oil pressure is correct.

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. Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from B6067 to D793/A2 013410

DIAG TRANSM. 2/4 PRESSx10 1/3 PRESSx10 TRANSM.TEMP CONV OUT TEMP

Function: 2.6.2 Sensor oil pressure Signal value: 0-5 bar

Short-circuiting to ground.

8-15 bar

Oil pressure is correct.

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. Circuit diagram: Circuit Dana TE 32000FF group 2.0 Connection: signal from B7660 to D793/H3 013410

DIAG TRANSM. 2/4 PRESSx10 1/3 PRESSx10 TRANSM.TEMP CONV OUT TEMP

Function: 2.7.2 Sensor engine rpm and oil temperature transmission 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. Circuit diagram: Circuit Dana TE 32000FF group 2.0 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.

Workshop manual DRF 400–450

VDRF03.02GB

98

8 Control system – 8.4.7.11 TRANSM, menu 11

8.4.7.11

TRANSM, menu 11

AXLE RATIO (transmission alternative Dana)

page –

Description: Drive axle gear ratio.

11(X) XXXXX XXXX XXXX

Circuit diagram: Connection: 006871

DIAG TRANSM. PRESENT VALUE AXLE RATIO RADIUS SPEED LIMIT

Function: 2.8 Control system, transmission Signal value: XXXXX = drive axle’s total gear ratio x 1024

RADIUS (transmission alternative Dana)

page –

Description: Drive wheels’ radius

11(X) XXXXX XXXX XXXX

Circuit diagram: Connection: 006871

DIAG TRANSM. PRESENT VALUE AXLE RATIO RADIUS SPEED LIMIT

Function: 2.8 Control system, transmission Signal value: XXXX = Drive wheels’ radius in mm.

SPEED LIMIT (transmission alternative Dana)

page –

Description: Speed limitation.

11(X) XXXXX XXXX XXXX

Circuit diagram: Connection: 006871

DIAG TRANSM. PRESENT VALUE AXLE RATIO RADIUS SPEED LIMIT

Function: 2.8 Control system, transmission Signal value: XXX = Speed limitation in km/h.

AXLE RATIOx1024 (transmission alternative Dana full flow)

page –

Description: Drive axle gear ratio. Circuit diagram: Connection: 013431

DIAG TRANSM. 11(X) PRESENT VALUE AXLE RATIOx1024 XXXXX RADIUS XXXX SPEED LIMIT XXXX

Function: 2.8 Control system, transmission Signal value: XXXXX = drive axle’s total gear ratio

RADIUS (transmission alternative Dana full flow)

page –

Description: Drive wheels’ radius Circuit diagram: Connection: 013431

DIAG TRANSM. 11(X) PRESENT VALUE AXLE RATIOx1024 XXXXX RADIUS XXXX SPEED LIMIT XXXX

Function: 2.8 Control system, transmission Signal value: XXXX = Drive wheels’ radius in mm.

SPEED LIMIT (transmission alternative Dana full flow)

page –

VDRF03.02GB

Description: Speed limitation. Circuit diagram: Connection: 013431

DIAG TRANSM. 11(X) PRESENT VALUE AXLE RATIOx1024 XXXXX RADIUS XXXX SPEED LIMIT XXXX

Function: 2.8 Control system, transmission Signal value: XXX = Speed limitation in km/h.

Workshop manual DRF 400–450

8 Control system – 8.4.7.12 TRANSM, menu 12

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. Circuit diagram: 000171

DIAG TRANSM. 13(15) ACT ERROR AREA XXX TYPE XXX NUMBER OF OCCU. XXXXX TIME AGO XXXXX

Connection: Function: 2.8 Control system, transmission Signal value: XXX = First part of error code; see section D Error codes.

TYPE

page –

Description: Indicates type of active error. Circuit diagram: Connection: 000171

DIAG TRANSM. 13(15) ACT ERROR AREA XXX TYPE XXX NUMBER OF OCCU. XXXXX TIME AGO XXXXX

Function: 2.8 Control system, transmission Signal value: XXX = Second part of error code.

NUMBER OF OCCU.

page –

Description: Number of times active errors have occurred. Circuit diagram: Connection: 000171

DIAG TRANSM. 13(15) ACT ERROR AREA XXX TYPE XXX NUMBER OF OCCU. XXXXX TIME AGO XXXXX

Function: 2.8 Control system, transmission Signal value: XXXXX = Number of times active errors have occurred.

TIME AGO

page –

Description: When latest active error occurred. Circuit diagram: Connection: 000171

DIAG TRANSM. 13(15) ACT ERROR AREA XXX TYPE XXX NUMBER OF OCCU. XXXXX TIME AGO XXXXX

Function: 2.8 Control system, transmission Signal value: XXXXX = Operating time in hours since latest error.

Workshop manual DRF 400–450

VDRF03.02GB

100

8 Control system – 8.4.7.14 TRANSM, menu 14

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. Circuit diagram: 006873

DIAG TRANSM. CONVERTER STATUS TORQUE IMPELLER TORQUE TURBINE

Connection: Function: 2.8 Control system, transmission 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. Circuit diagram: 006873

DIAG TRANSM. CONVERTER STATUS TORQUE IMPELLER TORQUE TURBINE

Connection: Function: 2.8 Control system, transmission Signal value: XXXX = Torque in Nm.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.8 BOOM

8.4.8

101

BOOM

BOOM, description

page –

This group covers the boom functions. Confirm selection with function key for Enter.

009275

DIAGNOSIS CAN/POWER LIGHTS CAB 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). Circuit diagram: Circuit Joystick group 7.1 Connection: signal from S815/8 to analogue in D790-1/K7:3 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). Circuit diagram: Circuit Joystick group 7.1 Connection: signal from S815/4 to analogue in D790-1/K7:4 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.

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

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.

Workshop manual DRF 400–450

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 RELIEVE PRESS. IN XY

Function: 7.3.7 Valve block extension cylinder 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.

BLOCK VALVES, RELIEVE PRESS. IN

page –

Description: Voltage feed to solenoid valve pump unloading. Circuit diagram: Circuit Boom in/out group 7.3 Connection: digital out from D797-R/K1:40 to B6062/1 012097

DIAG BOOM 2(8) BLOCK VALVES UP/DOWN LE XY RI XY IN XY RELIEVE PRESS. IN XY

Function: 7.3.9 Valve block pump unloading. 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.8.3 BOOM, menu 3

8.4.8.3

103

BOOM, menu 3

BOOM HIGH SPEED, UP

page –

Description: Voltage feed to solenoid valve, regeneration boom up. Circuit diagram: Circuit Boom up/down group 7.2 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

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.

BOOM HIGH SPEED, OUT

page –

Description: Voltage feed to solenoid valve, regeneration, extension. Circuit diagram: Circuit Boom in/out group 7.3 Connection: digital out from D797-R/K1:4 to B6046/1 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

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.

Workshop manual DRF 400–450

VDRF03.02GB

104

8 Control system – 8.4.8.4 BOOM, menu 4

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

Circuit diagram: Circuit Boom up/down group 7.2 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

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.

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

Circuit diagram: Circuit Boom up/down group 7.2 000178

DIAG BOOM OUTPUT BOOM UP REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal reference value out from D797-F/K1:16 to Y6005/2 Function: 7.2.5 Control valve lift, lower and extension 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

Circuit diagram: Circuit Boom up/down group 7.2 000178

DIAG BOOM OUTPUT BOOM UP REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal actual value out from D797-F/K1:16 to Y6005/2 Function: 7.2.5 Control valve lift, lower and extension Signal value: XXX = Measured current value in mA.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.8.5 BOOM, menu 5

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

Circuit diagram: Circuit Boom up/down group 7.2 000179

DIAG BOOM OUTPUT BOOM DOWN REFERENCE REQUIRED VALUE FEEDBACK

Connection: digital out from D797-F/K1:3 to Y6004/1 Function: 7.2.5 Control valve lift, lower and extension 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.

OUTPUT BOOM DOWN, REQUIRED VALUE

page –

Description: Reference value for control current to control valve lift, lower and extension (solenoid valve lower).

5(8) XY XXX XXX

Circuit diagram: Circuit Boom up/down group 7.2 000179

DIAG BOOM OUTPUT BOOM DOWN REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal reference value out from D797-F/K1:17 to Y6004/2 Function: 7.2.5 Control valve lift, lower and extension Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT BOOM DOWN, FEEDBACK

page –

Description: Present control current to control valve lift, lower and extension (solenoid valve lower).

5(8) XY XXX XXX

Circuit diagram: Circuit Boom up/down group 7.2 000179

DIAG BOOM OUTPUT BOOM DOWN REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal actual value out from D797-F/K1:17 to Y6004/2 Function: 7.2.5 Control valve lift, lower and extension Signal value: XXX = Measured current value in mA.

Workshop manual DRF 400–450

VDRF03.02GB

106

8 Control system – 8.4.8.6 BOOM, menu 6

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

Circuit diagram: Circuit Boom in/out group 7.3 000180

DIAG BOOM OUTPUT BOOM IN REFERENCE REQUIRED VALUE FEEDBACK

Connection: digital out from D797-F/K1:5 to Y6007/1 Function: 7.3.5 Control valve lift, lower and extension 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.

OUTPUT BOOM IN, REQUIRED VALUE

page –

Description: Reference value for control current to control valve lift, lower and extension (solenoid valve extension in).

6(8) XY XXX XXX

Circuit diagram: Circuit Boom in/out group 7.3 000180

DIAG BOOM OUTPUT BOOM IN REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal reference value out from D797-F/K1:19 to Y6007/2 Function: 7.3.5 Control valve lift, lower and extension Signal value: XXX = Current value: in mA for control of solenoid valve.

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

Circuit diagram: Circuit Boom in/out group 7.3 000180

DIAG BOOM OUTPUT BOOM IN REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal actual value out from D797-F/K1:19 to Y6007/2 Function: 7.3.5 Control valve lift, lower and extension Signal value: XXX = Measured current value in mA.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.8.7 BOOM, menu 7

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

Circuit diagram: Circuit Boom in/out group 7.3 000181

DIAG BOOM OUTPUT BOOM OUT REFERENCE REQUIRED VALUE FEEDBACK

Connection: digital out from D797-F/K1:4 to Y6006/1 Function: 7.3.5 Control valve lift, lower and extension 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.

OUTPUT BOOM OUT, REQUIRED VALUE

page –

Description: Reference value for control current to control valve lift, lower and extension (solenoid valve extension out).

7(8) XY XXX XXX

Circuit diagram: Circuit Boom in/out group 7.3 000181

DIAG BOOM OUTPUT BOOM OUT REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal reference value out from D797-F/K1:18 to Y6006/2 Function: 7.3.5 Control valve lift, lower and extension Signal value: XXX = Current value: in mA for control of solenoid valve.

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

Circuit diagram: Circuit Boom in/out group 7.3 000181

DIAG BOOM OUTPUT BOOM OUT REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal actual value out from D797-F/K1:18 to Y6006/2 Function: 7.3.5 Control valve lift, lower and extension Signal value: XXX = Measured current value in mA.

Workshop manual DRF 400–450

VDRF03.02GB

108

8 Control system – 8.4.8.8 BOOM, menu 8

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. Circuit diagram: Circuit OP + Scale group 8.2 000182

DIAG BOOM 8(8) PRESENT INPUT SIGNAL 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

Input signal active.

0

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) PRESENT INPUT SIGNAL 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 Mechanical overload system: 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

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.9 ATTACH

8.4.9

109

ATTACH

ATTACH, description

page –

This group covers attachment functions. Confirm selection with function key for Enter.

009276

DIAGNOSIS CAN/POWER LIGHTS CAB 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 Circuit diagram: Circuit Joystick group 7.1 Connection: signal from S815/11 to analogue in D790-1/K7:5 000184

DIAG ATTACHMENT 1(21) PRESENT INPUT SIGNALS 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 Circuit diagram: Circuit Joystick group 7.1 000184

DIAG ATTACHMENT 1(21) PRESENT INPUT SIGNALS ROT CW/CCW XX.XXV TILT IN/OUT XX.XXV

Connection: signal from S815/1 to analogue in D790-1/K7:6 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. Circuit diagram: Circuit Joystick group 7.1 000185

DIAG ATTACHMENT 2(21) PRESENT INPUT SIGNALS 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

Input signal active.

0

No signal.

Workshop manual DRF 400–450

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. Circuit diagram: Circuit Joystick group 7.1 Connection: from S815/19 to digital in D790-1/K7:16 000185

DIAG ATTACHMENT 2(21) PRESENT INPUT SIGNALS SIDE SHIFT LE X RI X PISTOL X 30/35 STOP X

Function: 7.5 Spreading, 7.10.2 Weight Indicator, 7.10.4 Synchronised lift Signal value: 1

Input signal active.

0

No signal.

PRESENT INPUT SIGNALS, 30/35 STOP

page –

Description: Signal from switch for stop at 30’/35’. Circuit diagram: Circuit Spreading Sensor group 7.5 000185

DIAG ATTACHMENT 2(21) PRESENT INPUT SIGNALS SIDE SHIFT LE X RI X PISTOL X 30/35 STOP X

Connection: from S1004/1 to digital in D790-1/K8:10 Function: 7.5 Spreading Signal value: 1

Input signal active.

0

No signal.

8.4.9.3

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

DIAG ATTACHMENT 3(21) PRESENT INPUT SIGNALS LOCK TW X UNLOCK TW X BY-PASS HEIGHT X

Function: 7.9.1 Twistlocks Signal value: 1

Input signal active.

0

No signal.

PRESENT INPUT SIGNALS, UNLOCK TW

page –

Description: Signal from control lever to unlock twistlock.

VDRF03.02GB

Circuit diagram: Circuit Joystick group 7.1 Connection: from S815/20 to digital in D790-1/K7:15 000186

DIAG ATTACHMENT 3(21) PRESENT INPUT SIGNALS LOCK TW X UNLOCK TW X BY-PASS HEIGHT X

Function: 7.9.1 Twistlocks Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.9.4 ATTACH, menu 4

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

DIAG ATTACHMENT 3(21) PRESENT INPUT SIGNALS 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

Input signal active.

0

No signal.

8.4.9.4

ATTACH, menu 4

PRESENT INPUT SIGNALS, TILT LOCKING

page –

Description: Signal from control lever for tilt locking. Circuit diagram: Circuit Joystick group 7.1 006874

DIAG ATTACHMENT 4(X) PRESENT INPUT SIGNALS TILT LOCKING X LEVELLING LOCKING X AUTO 20'-40' X

Connection: from S815/18 to digital in D790-1/K8:2 Function: 7.7 Tilt Signal value: 1

Input signal active.

0

No signal.

PRESENT INPUT SIGNALS, LEVELLING LOCKING

page –

Description: Signal from control lever for levelling lock. Circuit diagram: Circuit Joystick group 7.1 006874

DIAG ATTACHMENT 4(X) PRESENT INPUT SIGNALS TILT LOCKING X LEVELLING LOCKING X AUTO 20'-40' X

Connection: from S815/17 to digital in D790-1/K8:1 Function: 7.8 Levelling Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

112

8 Control system – 8.4.9.5 ATTACH, menu 5

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) PRESENT INPUT SIGNALS TILT LOCKING X LEVELLING LOCKING X AUTO 20'-40' X

Connection: from S199/-2 to digital in D790-1/K8:11 Function: 7.5 Spreading Signal value: 1

Input signal active.

0

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. Circuit diagram: Circuit Spreading Sensor group 7.5 000188

DIAG ATTACHMENT 5(21) PRESENT INPUT SIGNALS 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

Input signal active.

0

No signal.

PRESENT INPUT SIGNALS, 30/35 STOP

DIAG ATTACHMENT 5(21) PRESENT INPUT SIGNALS 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. Circuit diagram: Circuit Spreading Sensor group 7.5 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

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.9.6 ATTACH, menu 6

113

PRESENT INPUT SIGNALS, EXTENSION 60CM (model year -2008)

page –

Description: Signal from position sensor extension 60 cm, for fixed scale. 000188

DIAG ATTACHMENT 5(21) PRESENT INPUT SIGNALS LOW SPEED 20/40 X 30/35 STOP X EXTENSION 60CM X

Circuit diagram: Circuit OP + Scale group 8.2 Connection: from inductive sensor B7224/C to digital in D791-1/K1:21 Function: 7.10.2 Weight indicator Signal value: 1

Input signal active.

0

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. Circuit diagram: Circuit Twistlock group 7.9 Connection: LE: signal from B7202L/C to analogue in (used as digital) D791-1/K1:13

000202

DIAG ATTACHMENT 6(21) PRESENT INPUT SIGNALS 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

Input signal active.

0

No signal.

PRESENT INPUT SIGNALS, ALIGNMENT, REAR

page –

Description: Signals from sensors alignment right rear and left rear. Circuit diagram: Circuit Twistlock group 7.9 Connection: LE: signal from B7203L/C to analogue in (used as digital) D791-1/K1:27

000202

DIAG ATTACHMENT 6(21) PRESENT INPUT SIGNALS ALIGNMENT LE RI FRONT X X REAR X X

RI: signal from B7203R/C to digital in D791-1/K1:26 Function: 7.9.1.8 Alignment sensor Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

114

8 Control system – 8.4.9.7 ATTACH, menu 7

8.4.9.7

ATTACH, menu 7

PRESENT INPUT SIGNAL, LOCKED TW

page –

Description: Signals from sensors locked twistlock right and left. Circuit diagram: Circuit Twistlock group 7.9 Connection: LE: signal from B7205L/C to analogue in (used as digital) D791-1/K1:23

001633

DIAG ATTACHMENT 7(21) PRESENT INPUT SIGNALS 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

Input signal active.

0

No signal.

PRESENT OUTPUT SIGNAL, UNLOCKED TW

page –

Description: Signals from sensors open twistlock right and left. Circuit diagram: Circuit Twistlock group 7.9 Connection: LE: signal from B7204L/C to analogue in (used as digital) D791-1/K1:22

001633

DIAG ATTACHMENT 7(21) PRESENT INPUT SIGNALS 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

1

Output signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.9.8 ATTACH, menu 8

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. Circuit diagram: Circuit Spreading Valves group 7.5 Connection: digital out from D791-1/K1:31 to Y6020/1 000189

DIAG ATTACHMENT 8(21) PRESENT OUTPUT SIGNAL SIDE SHIFT LEFT XY SIDE SHIFT RIGHT XY

Function: 7.4.3 Control valve attachment 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.

PRESENT OUTPUT SIGNAL, SIDE SHIFT RIGHT

page –

Description: Voltage feed to control valve attachment, side shift right. Circuit diagram: Circuit Spreading Valves group 7.5 Connection: digital out from D791-1/K1:30 to Y6021/1 000189

DIAG ATTACHMENT 8(21) PRESENT OUTPUT SIGNAL SIDE SHIFT LEFT XY SIDE SHIFT RIGHT XY

Function: 7.4.3 Control valve attachment 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.

Workshop manual DRF 400–450

VDRF03.02GB

116

8 Control system – 8.4.9.9 ATTACH, menu 9

8.4.9.9

ATTACH, menu 9

PRESENT OUTPUT SIGNAL, LOCK TW

page –

Description: Voltage feed to attachment control valve, lock twistlock. Circuit diagram: Circuit Twistlock group 7.9 Connection: digital out from D791-1/K1:32 to Y6040/1 000190

DIAG ATTACHMENT 9(21) PRESENT OUTPUT SIGNAL LOCK TW XY UNLOCK TW XY

Function: 7.9.1.3 Attachment control valve 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.

PRESENT OUTPUT SIGNAL, UNLOCK TW

page –

Description: Voltage feed to control valve attachment, open twistlock. Circuit diagram: Circuit Twistlock group 7.9 Connection: digital out from D791-1/K1:33 to Y6039/1 000190

DIAG ATTACHMENT 9(21) PRESENT OUTPUT SIGNAL LOCK TW XY UNLOCK TW XY

Function: 7.9.1.3 Attachment control valve 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.9.10 ATTACH, menu 10

8.4.9.10

117

ATTACH, menu 10

PRESENT OUTPUT SIGNAL, IND. LOCKED TW

page –

Description: Voltage feed indicator light locked twistlock. Circuit diagram: Circuit Twistlock group 7.9 Connection: digital out from D791-1/K1:39 to H563/1 000191

DIAG ATTACHMENT 10(21) PRESENT OUTPUT SIGNAL IND. LOCKED TW XY IND. UNLOCKED TW XY IND. ALIGNMENT XY

Function: 7.9.1 Twistlocks 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.

PRESENT OUTPUT SIGNAL, IND. UNLOCKED TW

page –

Description: Voltage feed indicator light open twistlock. Circuit diagram: Circuit Twistlock group 7.9 Connection: digital out from D791-1/K1:25 to H562/1 000191

DIAG ATTACHMENT 10(21) PRESENT OUTPUT SIGNAL IND. LOCKED TW XY IND. UNLOCKED TW XY IND. ALIGNMENT XY

Function: 7.9.1 Twistlocks 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.

Workshop manual DRF 400–450

VDRF03.02GB

118

8 Control system – 8.4.9.11 ATTACH, menu 11

PRESENT OUTPUT SIGNAL, ALIGNMENT

page –

Description: Voltage feed indicator light alignment. Circuit diagram: Circuit Twistlock group 7.9 Connection: digital out from D791-1/K1:29 to H564/2 000191

DIAG ATTACHMENT 10(21) PRESENT OUTPUT SIGNAL IND. LOCKED TW XY IND. UNLOCKED TW XY IND. ALIGNMENT XY

Function: 7.9.1 Twistlocks 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.

8.4.9.11

ATTACH, menu 11

OUTPUT ROTATION C.W., REFERENCE

page –

Description: Status control current to control valve attachment for rotation clockwise. Circuit diagram: Circuit Rotation, group 7.6 000192

DIAG ATTACHMENT 11(21) OUTPUT ROTATION C.W. REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791-1/K1:2 to solenoid valve Y6008/1 Function: 7.6.3 Control valve attachment 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.9.12 ATTACH, menu 12

119

OUTPUT ROTATION C.W., REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for rotation clockwise. Circuit diagram: Circuit Rotation, group 7.6 000192

DIAG ATTACHMENT 11(21) OUTPUT ROTATION C.W. REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D791-1/K1:16 to Y6008/2 Function: 7.6.3 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT ROTATION C.W., FEEDBACK

page –

Description: Present control current to control valve attachment for rotation clockwise. Circuit diagram: Circuit Rotation, group 7.6 000192

DIAG ATTACHMENT 11(21) OUTPUT ROTATION C.W. REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal, actual value out from D791-1/K1:16 to Y6008/2 Function: 7.6.3 Control valve attachment Signal value: XXX = Measured current value in mA.

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. Circuit diagram: Circuit Rotation, group 7.6 000193

DIAG ATTACHMENT 12(21) 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 Function: 7.6.3 Control valve attachment 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.

OUTPUT ROTATION C.C.W., REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for rotation anticlockwise. Circuit diagram: Circuit Rotation, group 7.6 000193

DIAG ATTACHMENT 12(21) OUTPUT ROTATION C.C.W. REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D791-1/K1:17 to Y6009/2 Function: 7.6.3 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

120

8 Control system – 8.4.9.13 ATTACH, menu 13

OUTPUT ROTATION C.C.W., FEEDBACK

page –

Description: Present control current to control valve attachment for rotation clockwise. Circuit diagram: Circuit Rotation, group 7.6 000193

DIAG ATTACHMENT 12(21) OUTPUT ROTATION C.C.W. REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal, actual value out from D791-1/K1:17 to Y6009/2 Function: 7.6.3 Control valve attachment Signal value: XXX = Measured current value in mA.

8.4.9.13

ATTACH, menu 13

OUTPUT SPREADER OUT, REFERENCE

page –

Description: Status control current to control valve attachment for spreader out. Circuit diagram: Circuit Spreading Valves group 7.5 000194

DIAG ATTACHMENT 13(21) OUTPUT SPREADER OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791-1/K1:4 to Y6018/1 Function: 7.5.3 Control valve attachment 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.

OUTPUT SPREADER OUT, REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for output signal, spreading out. Circuit diagram: Circuit Spreading Valves group 7.5 000194

DIAG ATTACHMENT 13(21) OUTPUT SPREADER OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D791-1/K1:18 to Y6018/2 Function: 7.5.3 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER OUT, FEEDBACK

page –

Description: Present control current to control valve attachment for spreader out. Circuit diagram: Circuit Spreading Valves group 7.5 000194

DIAG ATTACHMENT 13(21) OUTPUT SPREADER OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal, actual value out from D791-1/K1:18 to Y6018/2 Function: 7.5.3 Control valve attachment Signal value: XXX = Measured current value in mA.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.9.14 ATTACH, menu 14

8.4.9.14

121

ATTACH, menu 14

OUTPUT SPREADER IN, REFERENCE

page –

Description: Status control current to control valve attachment for spreader in. Circuit diagram: Circuit Spreading Valves group 7.5 000195

DIAG ATTACHMENT 14(21) OUTPUT SPREADER IN REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791-1/K1:5 to Y6019/1 Function: 7.5.3 Control valve attachment 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.

OUTPUT SPREADER IN, REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for spreading in. Circuit diagram: Circuit Spreading Valves group 7.5 000195

DIAG ATTACHMENT 14(21) OUTPUT SPREADER IN REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal, reference value out from D791-1/K1:19 to Y6019/2 Function: 7.5.3 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER IN, FEEDBACK

page –

Description: Present control current to control valve attachment for spreader in. Circuit diagram: Circuit Spreading Valves group 7.5 000195

DIAG ATTACHMENT 14(21) OUTPUT SPREADER IN REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal, actual value out from D791-1/K1:19 to Y6019/2 Function: 7.5.3 Control valve attachment Signal value: XXX = Measured current value in mA.

Workshop manual DRF 400–450

VDRF03.02GB

122

8 Control system – 8.4.9.15 ATTACH, menu 15

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) PRESENT OUTPUT SIGNAL 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

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.

PRESENT OUTPUT SIGNAL, TILT LOCKING 2

page –

Description: Voltage feed to lock valve tilt. Circuit diagram: Circuit Tilt locking group 7.7 006875

DIAG ATTACHMENT 15(X) PRESENT OUTPUT SIGNAL TILT LOCKING 1 XY TILT LOCKING 2 XY BUZZER AUTO 20-40 XY

Connection: digital out from D791-1/K1:9 to Y6012-2/1 Function: 7.7.4 Lock valve tilt 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.9.16 ATTACH, menu 16

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

DIAG ATTACHMENT 15(X) PRESENT OUTPUT SIGNAL TILT LOCKING 1 XY TILT LOCKING 2 XY BUZZER AUTO 20-40 XY

Connection: digital out from D791-1/K1:28 to H9003/1 Function: 7.5 Spreading 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.

8.4.9.16

ATTACH, menu 16

OUTPUT TILT OUT, REFERENCE

page –

Description: Status control current to control valve attachment for tilt out. 000197

DIAG ATTACHMENT 16(21) 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 Function: 7.7.5 Control valve attachment 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.

Workshop manual DRF 400–450

VDRF03.02GB

124

8 Control system – 8.4.9.16 ATTACH, menu 16

OUTPUT TILT OUT, REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for tilt out. 000197

DIAG ATTACHMENT 16(21) OUTPUT TILT OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 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 Function: 7.7.5 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT TILT OUT, FEEDBACK

page –

Description: Present control current to control valve attachment for tilt out. 000197

DIAG ATTACHMENT 16(21) OUTPUT TILT OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 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 Function: 7.7.5 Control valve attachment Signal value: XXX = Measured current value in mA.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.9.17 ATTACH, menu 17

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

DIAG ATTACHMENT 17(21) OUTPUT TILT IN REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: digital out from D791-2/K1:5 to Y6011/1 Combi attachment: digital out from D791-4/K1:3 to Y6011/1 Function: 7.7.5 Control valve attachment 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.

OUTPUT TILT IN, REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for tilt in. 000198

DIAG ATTACHMENT 17(21) OUTPUT TILT IN REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: output signal reference value out from D7912/K1:19 to Y6011/2 Combi attachment: output signal reference value out from D7914/K1:17 to Y6011/2 Function: 7.7.5 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

126

8 Control system – 8.4.9.18 ATTACH, menu 18

OUTPUT TILT IN, FEEDBACK

page –

Description: Present control current to control valve attachment for tilt in. 000198

DIAG ATTACHMENT 17(21) OUTPUT TILT IN REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: output signal actual value out from D791-2/ K1:19 to Y6011/2 Combi attachment: output signal actual value out from D791-4/ K1:17 to Y6011/2 Function: 7.7.5 Control valve attachment Signal value: XXX = Measured current value in mA.

8.4.9.18

ATTACH, menu 18

PRESENT OUTPUT SIGNAL, LOCK LEVELLING 1

page –

Description: Voltage feed to lock valve levelling. Circuit diagram: Circuit Tilt + Levelling group 7.7 000199

DIAG ATTACHMENT 18(21) PRESENT OUTPUT SIGNAL 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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.9.19 ATTACH, menu 19

127

PRESENT OUTPUT SIGNAL, LOCK LEVELLING 2

page –

Description: Voltage feed to lock valve levelling. Connection: Circuit Tilt + Levelling group 7.7 000199

DIAG ATTACHMENT 18(21) PRESENT OUTPUT SIGNAL 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

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.

8.4.9.19

ATTACH, menu 19

OUTPUT LEVELLING RI, REFERENCE

page –

Description: Status control current to control valve attachment for levelling right. 000200

DIAG ATTACHMENT 19(21) OUTPUT LEVELLING RI REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: digital out from D791-2/K1:2 to Y6035/1 Combi attachment: digital out from D791-3/K1:2 to Y6035/1 Function: 7.8.3 Control valve attachment 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.

Workshop manual DRF 400–450

VDRF03.02GB

128

8 Control system – 8.4.9.19 ATTACH, menu 19

OUTPUT LEVELLING RI, REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for levelling right. 000200

DIAG ATTACHMENT 19(21) OUTPUT LEVELLING RI REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: output signal reference value out from D7912/K1:16 to Y6035/2 Combi attachment: output signal reference value out from D7913/K1:16 to Y6035/2 Function: 7.8.3 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LEVELLING RI, FEEDBACK

page –

Description: Present control current to control valve attachment for levelling right. 000200

DIAG ATTACHMENT 19(21) OUTPUT LEVELLING RI REFERENCE XY RQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: output signal actual value out from D791-2/ K1:16 to Y6035/2 Combi attachment: output signal actual value out from D791-3/ K1:16 to Y6035/2 Function: 7.8.3 Control valve attachment Signal value: XXX = Measured current value in mA.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.9.20 ATTACH, menu 20

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

DIAG ATTACHMENT 20(X) OUTPUT LEVELLING LE REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: digital out from D791-2/K1:3 to Y6036/2 Combi attachment: digital out from D791-3/K1:3 to Y6036/2 Function: 7.8.3 Control valve attachment 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.

OUTPUT LEVELLING LE, REQUIRED VALUE

page –

Description: Reference value for control current to control valve attachment for levelling left. 006876

DIAG ATTACHMENT 20(X) OUTPUT LEVELLING LE REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: output signal reference value out from D7912/K1:17 to Y6036/2 Combi attachment: output signal reference value out from D7913/K1:17 to Y6036/2 Function: 7.8.3 Control valve attachment Signal value: XXX = Current value: in mA for control of solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

130

8 Control system – 8.4.9.21 ATTACH, menu 21

OUTPUT LEVELLING LE, FEEDBACK

page –

Description: Present control current to control valve attachment for levelling left. 006876

DIAG ATTACHMENT 20(X) OUTPUT LEVELLING LE REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Circuit diagram: Circuit Tilt + Levelling group 7.7 Connection: Top lift attachment: output signal actual value out from D791-2/ K1:17 to Y6036/2 Combi attachment: output signal actual value out from D791-3/ K1:17 to Y6036/2 Function: 7.8.3 Control valve attachment Signal value: XXX = Measured current value in mA.

8.4.9.21

ATTACH, menu 21

ROTATION STOP, SWITCH

page –

Description: Signal from rotation stop switch. Circuit diagram: Circuit Bypass group 8.2 006877

DIAG ATTACHMENT 21(X) PRESENT INPUT SIGNALS 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

Input signal active.

0

No signal.

ROTATION STOP, SENSOR STOP

page –

Description: Signal from sensor rotation stop, with rotation 25 °. Circuit diagram: Circuit Rotation, group 7.6 006877

DIAG ATTACHMENT 21(X) PRESENT INPUT SIGNALS 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

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.9.22 ATTACH, menu 22

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

DIAG ATTACHMENT 22(X) PRESENT INPUT SIGNAL 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

DIAG ATTACHMENT 22(X) PRESENT INPUT SIGNAL LENGTH TO CONTAINER (cm) XXXX DAMP DOWN X

Connection: Function: 7.2 Lifting/lowering Signal value: 1

Damping active.

0

No damping.

Workshop manual DRF 400–450

VDRF03.02GB

132

8 Control system – 8.4.10 OP

8.4.10

OP

OP, description

page –

This group covers the overload system functions. Confirm selection with function key for Enter.

009277

DIAGNOSIS CAN/POWER LIGHTS CAB 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. Circuit diagram: Circuit OP + Scale group 8.2 008203

DIAG OP 1(X) PRESENT INPUT SIGNAL 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) PRESENT INPUT SIGNAL STEERING AXLE X X BOOM ANGLE X EXTENSION X

Circuit diagram: Circuit OP + Scale group 8.2 Connection: signal from B771/3 to analogue in D797-R/K1:21 Function: 8.2.1.2 Sensor, boom angle Signal value:

VDRF03.02GB

1

Input signal active. Boom angle over 35 °.

0

No signal. Boom angle under 35 °.

Workshop manual DRF 400–450

8 Control system – 8.4.10.2 OP, menu 2

133

PRESENT INPUT SIGNAL, EXTENSION (model year -2008)

DIAG OP 1(X) PRESENT INPUT SIGNAL 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. Circuit diagram: Circuit OP + Scale group 8.2 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.

0

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) PRESENT INPUT SIGNAL

Circuit diagram: Circuit Bypass group 8.2

X

000206

Connection: signal from S1005/1 to digital in D790-1/K8:3

BY-PASS

Function: 7.1.3 Bypass switch Signal value: 1

Input signal active. Signal is only active for max. 60 seconds.

0

No signal.

Workshop manual DRF 400–450

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8 Control system – 8.4.10.3 OP, menu 3

8.4.10.3

OP, menu 3

PRESENT INPUT SIGNAL LIFT CYL LE RI, C-

page –

DIAG OP 3(5) PRESENT INPUT SIGNAL 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). Circuit diagram: Circuit OP + Scale group 8.2 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 Function: 7.2.9 Sensor hydraulic pressure lift cylinder

1

000207

2

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) PRESENT INPUT SIGNAL 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. Circuit diagram: Circuit OP + Scale group 8.2 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 Function: 7.2.9 Sensor hydraulic pressure lift cylinder Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.

2

000207

1

1. Pressure C2.Pressure C+

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.10.4 OP, menu 4

8.4.10.4

135

OP, menu 4

PRESENT INPUT SIGNAL, BOOM ANGLE

page –

(Standard model year 2009-) Description: Signal from sensor boom angle. Circuit diagram: Circuit OP + Scale group 8.2 000208

DIAG OP 4(5) PRESENT INPUT SIGNAL BOOM ANGLE X.XXV BOOM EXTENSION X.XXV

Connection: signal from B771/3 to analogue in D797-R/K1:21 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). Circuit diagram: Circuit OP + Scale group 8.2 000208

DIAG OP 4(5) PRESENT INPUT SIGNAL BOOM ANGLE X.XXV BOOM EXTENSION X.XXV

Connection: signal from B777/3 to analogue in D797-R/K1:22 Function: 7.3.11 Sensor, boom length Signal value: X.XXV = 0.03 - 4.50 V

8.4.10.5

OP, menu 5

ALLOWED LOAD

page –

Description: Permitted load at the current load centre. Circuit diagram: Connection: 006879

DIAG OP 5(X) ALLOWED LOAD XXXXXkg PRESENT LOAD XXXXXkg LOAD STR.AXLE XXXXXkg LOAD-CENTER XX.XXm

Function: 8.2.1 Overload system Signal value: XXXXkg = Weight in kg.

PRESENT LOAD

page –

Description: Calculated load. Circuit diagram: Connection: 006879

DIAG OP 5(X) ALLOWED LOAD XXXXXkg PRESENT LOAD XXXXXkg LOAD STR.AXLE XXXXXkg LOAD-CENTER XX.XXm

Function: 8.2.1 Overload system Signal value: XXXXkg = Weight in kg.

LOAD STR.AXLE

page –

Description: Estimated load on the steering axle. Circuit diagram: Connection: 006879

DIAG OP 5(X) ALLOWED LOAD XXXXXkg PRESENT LOAD XXXXXkg LOAD STR.AXLE XXXXXkg LOAD-CENTER XX.XXm

Function: 8.2.1 Overload system Signal value: XXXXkg = Weight in kg.

Workshop manual DRF 400–450

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8 Control system – 8.4.10.6 OP, menu 6

LOAD-CENTRE

page –

Description: Horizontal distance between centre drive axle and load centre. Circuit diagram: 006879

DIAG OP 5(X) ALLOWED LOAD XXXXXkg PRESENT LOAD XXXXXkg LOAD STR.AXLE XXXXXkg 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

Circuit diagram: Connection: 006880

DIAG OP BOOM ANGLE EXTENSION BOOM HEIGHT BOOM HEIGHT-NOSE

Function: 8.2.1 Overload system Signal value: XXX = boom angle in °.

BOOM EXTENSION

page –

Description: Current boom extension.

6(X) XXX XXX XXX XXX

Circuit diagram: Connection: 006880

DIAG OP BOOM ANGLE EXTENSION BOOM HEIGHT BOOM HEIGHT-NOSE

Function: 8.2.1 Overload system 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 machine’s total height. Circuit diagram: 006880

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 attachment’s fixing point in the boom, suspension. The height is used to calculate the load’s centre of gravity as a part of the overload system. Circuit diagram: 006880

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

Workshop manual DRF 400–450

8 Control system – 8.4.11 EXTRA

8.4.11

137

EXTRA

EXTRA, description

page –

This menu consists of optional functions: 009278

DIAGNOSIS CAN/POWER LIGHTS CAB 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. Confirm selection with function key for Enter.

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

Circuit diagram: Circuit Combi Att group 7.9 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

1/0

Input signal active, jack up

0/1

Input signal active, jack down

0/0

No signal.

2

000212

3

1. Knee 2.Jack 3.Clamping plate

Workshop manual DRF 400–450

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 FRONT LEG UP/DOWN X/Y REAR LEG UP/DOWN X/Y CLAMP IN/OUT X/Y

Circuit diagram: Circuit Combi Att group 7.9 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 Function: 7.9.2 Lifting jacks Signal value:

1

1/0

Input signal active, jack up

0/1

Input signal active, jack down

0/0

No signal.

2

000212

3

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 FRONT LEG UP/DOWN X/Y REAR LEG UP/DOWN X/Y CLAMP IN/OUT X/Y

Circuit diagram: Circuit Combi Att group 7.9 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 Function: 7.9.2 Lifting jacks Signal value:

1

2

1/0

Input signal active, jack up

0/1

Input signal active, jack down

0/0

No signal.

000212

3

1. Knee 2.Jack 3.Clamping plate

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

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) PRESENT INPUT SIGNAL CLAMPING SENSORS FRONT LEGS LE X RI X REAR LEGS LE X RI X

Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7215L/C to digital in D791-3/K1:36 RI: signal from B7215R/C to digital in D791-4/K1:36 Function: 7.9.2.15 Sensor clamping position Signal value: 1

Input signal active.

0

No signal.

000214

1

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) PRESENT INPUT SIGNAL CLAMPING SENSORS FRONT LEGS LE X RI X REAR LEGS LE X RI X

Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7216L/C to digital in D791-3/K1:37 RI: signal from B7216R/C to digital in D791-4/K1:37 Function: 7.9.2.15 Sensor clamping position Signal value: 1

Input signal active.

0

No signal.

000214

1

1. Sensor clamping position

Workshop manual DRF 400–450

VDRF03.02GB

140

8 Control system – 8.4.11.1 COMBI

COMBI, menu 3

page –

PRESENT INPUT SIGNAL ALIGNMENT SENSORS, FRONT LEGS Description: Signal from sensor alignment front (load secured).

DIAG COMBI 3(17) PRESENT INPUT SIGNAL ALIGNMENT SENSORS FRONT LEGS LE X RI X REAR LEGS LE X RI X

Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7213L/C to digital in D791-3/K1:13 RI: signal from B7213R/C to digital in D791-4/K1:13 Function: 7.9.2.14 Sensor, alignment Signal value: 1

Input signal active.

0

No signal.

000216

1

1. Alignment sensor

PRESENT INPUT SIGNAL ALIGNMENT SENSORS, REAR LEGS Description: Signal from sensor alignment rear (load secured).

DIAG COMBI 3(17) PRESENT INPUT SIGNAL ALIGNMENT SENSORS FRONT LEGS LE X RI X REAR LEGS LE X RI X

Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7214L/C to digital in D791-3/K1:20 RI: signal from B7214R/C to digital in D791-4/K1:20 Function: 7.9.2.14 Sensor, alignment Signal value: 1

Input signal active.

0

No signal.

000216

1

1. Alignment sensor

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

141

COMBI, menu 4

page –

PRESENT INPUT SIGNAL END POS SENSORS FRONT, KNEE Description: Signal from sensor knee front. Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7217L/C to digital in D791-3/K1:21

000217

DIAG COMBI 4(17) PRESENT INPUT SIGNAL END POS SENSORS FRONT KNEE LE X RI X LEG LE X RI X

RI: signal from B7217R/C to digital in D791-4/K1:21 Function: 7.9.2.10 Sensor knee Signal value: 1

Input signal active. In motion.

0

No signal.

PRESENT INPUT SIGNAL END POS SENSORS FRONT, LEG Description: Signal from sensor lifting jacks front. Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7219L/C to digital in D791-3/K1:23

000217

DIAG COMBI 4(17) PRESENT INPUT SIGNAL END POS SENSORS FRONT KNEE LE X RI X LEG LE X RI X

RI: signal from B7219R/C to digital in D791-4/K1:23 Function: 7.9.2.13 Sensor, lifting jacks Signal value: 1

Input signal active. In motion.

0

No signal.

COMBI, menu 5

page –

PRESENT INPUT SIGNAL END POS SENSORS REAR, KNEE Description: Signal from sensor knee rear. Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7218L/C to digital in D791-3/K1:22

000218

DIAG COMBI 5(17) PRESENT INPUT SIGNAL END POS SENSORS REAR KNEE LE X RI X LEG LE X RI X

RI: signal from B7218R/C to digital in D791-4/K1:22 Function: 7.9.2.10 Sensor knee Signal value: 1

Input signal active. In motion.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

142

8 Control system – 8.4.11.1 COMBI

PRESENT INPUT SIGNAL END POS SENSORS REAR, LEG Description: Signal from sensor lifting jacks rear Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7220L/C to digital in D791-3/K1:24

000218

DIAG COMBI 5(17) PRESENT INPUT SIGNAL END POS SENSORS REAR KNEE LE X RI X LEG LE X RI X

RI: signal from B7220R/C to digital in D791-4/K1:24 Function: 7.9.2.13 Sensor, lifting jacks Signal value: 1

Input signal active. In motion.

0

No signal.

COMBI, menu 6

page –

PRESENT INPUT SIGNAL LEGS IN DRIVE, POSITION Description: Signal from sensor operating position. Circuit diagram: Circuit Combi Att group 7.9 Connection: LE: signal from B7212L/C to digital in D791-3/K1:40

000219

DIAG COMBI 6(17) PRESENT INPUT SIGNAL LEGS IN DRIVE POSITION LE X RI X

RI: signal from B7212R/C to digital in D791-4/K1:40 Function: 7.9.2.9 Sensor operating position Signal value:

VDRF03.02GB

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

143

COMBI, menu 7

page –

INDICATION LAMPS ALIGNMENT, FRONT Description: Voltage feed to indicator light alignment front. Circuit diagram: Circuit Combi Att group 7.9 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 Function: 7.9.2 Lifting jacks 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.

INDICATION LAMPS ALIGNMENT, REAR Description: Status for voltage feed to indicator light alignment rear. Circuit diagram: Circuit Combi Att group 7.9 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 Function: 7.9.2 Lifting jacks 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.

Workshop manual DRF 400–450

VDRF03.02GB

144

8 Control system – 8.4.11.1 COMBI

COMBI, menu 8

page –

INDICATION LAMPS CLAMP, FRONT Description: Status for voltage feed to indicator light clamping position front. Circuit diagram: Circuit Combi Att group 7.9 000221

DIAG COMBI 8(17) INDICATION LAMPS CLAMP FRONT XY REAR XY

Connection: digital out from D791-4/K1:29 to H578/1 Function: 7.9.2 Lifting jacks 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.

INDICATION LAMPS CLAMP, REAR Description: Status for voltage feed to indicator light clamping position rear. Circuit diagram: Circuit Combi Att group 7.9 000221

DIAG COMBI 8(17) INDICATION LAMPS CLAMP FRONT XY REAR XY

Connection: digital out from D791-4/K1:39 to H579/1 Function: 7.9.2 Lifting jacks 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

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

Circuit diagram: Circuit Combi Att group 7.9

XY XY

000222

Connection: digital out from D791-4/K1:10 to H580/1

FRONT LEGS UP FRONT LEGS DOWN

Function: 7.9.2 Lifting jacks 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.

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

Circuit diagram: Circuit Combi Att group 7.9 Connection: digital out from D791-4/K1:25 to H581/1 Function: 7.9.2 Lifting jacks 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.

Workshop manual DRF 400–450

VDRF03.02GB

146

8 Control system – 8.4.11.1 COMBI

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. Circuit diagram: Circuit Combi Att group 7.9 000223

DIAG COMBI 10(17) PRESENT OUTPUT SIGNAL 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

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.

PRESENT OUTPUT SIGNAL FRONT LEGS DOWN, LEGS Description: Status for voltage feed to control valve lifting jacks, solenoid valve front jacks down. Circuit diagram: Circuit Combi Att group 7.9 000223

DIAG COMBI 10(17) PRESENT OUTPUT SIGNAL FRONT LEGS DOWN KNEE LE XY RI XY LEGS LE XY RI XY

Connection: LE: digital out from D791-3/K1:32 to Y6013L/1 RI: digital out from D791-4/K1:32 to Y6013R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

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. Circuit diagram: Circuit Combi Att group 7.9 000224

DIAG COMBI 11(17) PRESENT OUTPUT SIGNAL FRONT LEGS UP KNEE LE XY RI XY LEGS LE XY RI XY

Connection: LE: digital out from D791-3/K1:4 to Y6057L/1 RI: digital out from D791-4/K1:4 to Y6057R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

PRESENT OUTPUT SIGNAL FRONT LEGS UP, LEGS Description: Status for voltage feed to control valve lifting jacks, solenoid valve front jacks up. Circuit diagram: Circuit Combi Att group 7.9 000224

DIAG COMBI 11(17) PRESENT OUTPUT SIGNAL FRONT LEGS UP KNEE LE XY RI XY LEGS LE XY RI XY

Connection: LE: digital out from D791-3/K1:33 to Y6060L/1 RI: digital out from D791-4/K1:33 to Y6060R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

Workshop manual DRF 400–450

VDRF03.02GB

148

8 Control system – 8.4.11.1 COMBI

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. Circuit diagram: Circuit Combi Att group 7.9 000225

DIAG COMBI 12(17) PRESENT OUTPUT SIGNAL REAR LEGS DOWN KNEE LE XY RI XY LEGS LE XY RI XY

Connection: LE: digital out from D791-3/K1:31 to Y6058L/1 RI: digital out from D791-4/K1:31 to Y6058R/1 Function: 7.9.2.3 Solenoid valve lifting jacks 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.

PRESENT OUTPUT SIGNAL REAR LEGS DOWN, LEGS Description: Status for voltage feed to control valve lifting jacks, solenoid valve rear jacks down. Circuit diagram: Circuit Combi Att group 7.9 000225

DIAG COMBI 12(17) PRESENT OUTPUT SIGNAL REAR LEGS DOWN KNEE LE XY RI XY LEGS LE XY RI XY

Connection: LE: digital out from D791-3/K1:7 to Y6014L/1 RI: digital out from D791-4/K1:7 to Y6014R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

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. Circuit diagram: Circuit Combi Att group 7.9 000226

DIAG COMBI 13(17) PRESENT OUTPUT SIGNAL REAR LEGS UP KNEE LE XY RI XY LEGS LE XY RI XY

Connection: LE: digital out from D791-3/K1:30 to Y6059L/1 RI: digital out from D791-4/K1:30 to Y6059R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

PRESENT OUTPUT SIGNAL REAR LEGS UP, LEGS Description: Status for voltage feed to control valve lifting jacks, solenoid valve rear jacks up. Circuit diagram: Circuit Combi Att group 7.9 000226

DIAG COMBI 13(17) PRESENT OUTPUT SIGNAL REAR LEGS UP KNEE LE XY RI XY LEGS LE XY RI XY

Connection: LE: digital out from D791-3/K1:9 to Y6061L/1 RI: digital out from D791-4/K1:9 to Y6061R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

Workshop manual DRF 400–450

VDRF03.02GB

150

8 Control system – 8.4.11.1 COMBI

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

Circuit diagram: Circuit Combi Att group 7.9 Connection: 000227

DIAG COMBI SEQUENCE MODE

Function: 7.9.2 Lifting jacks Signal value: 0

Sequence error

1

Jack up (0), knee in (0).

2

Jack up (0), knee moving (1).

3

Jack up (0), knee out (0).

4

Jack moving (1), knee out (0).

5

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

Circuit diagram: Circuit Combi Att group 7.9 Connection: 000227

DIAG COMBI SEQUENCE MODE

Function: 7.9.2 Lifting jacks Signal value: 0

Sequence error

1

Jack up (0), knee in (0).

2

Jack up (0), knee moving (1).

3

Jack up (0), knee out (0).

4

Jack moving (1), knee out (0).

5

Jack down (0), knee out (0). No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

151

COMBI, menu 15

page –

PRESENT OUTPUT SIGNAL CLAMP, OUT Description: Status for voltage feed to control valve lifting jacks, solenoid valve clamp release. Circuit diagram: Circuit Combi Att group 7.9 006881

DIAG COMBI 15(X) PRESENT OUTPUT SIGNAL CLAMP IN LE XY RI XY OUT LE XY RI XY

Connection: LE: digital out from D791-3/K1:12 to Y6055L/1 RI: digital out from D797-4/K1:12 to Y6055R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

PRESENT OUTPUT SIGNAL CLAMP, IN Description: Status for voltage feed to control valve lifting jacks, solenoid valve clamp. Circuit diagram: Circuit Combi Att group 7.9 006881

DIAG COMBI 15(X) PRESENT OUTPUT SIGNAL CLAMP IN LE XY RI XY OUT LE XY RI XY

Connection: LE: digital out from D791-3/K1:11 to Y6054L/1 RI: digital out from D797-4/K1:11 to Y6054R/1 Function: 7.9.2.3 Control valve lifting jacks 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.

Workshop manual DRF 400–450

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152

8 Control system – 8.4.11.1 COMBI

COMBI, menu 16

page –

PRESENT OUTPUT SIGNAL DRIVE POSITION

DIAG COMBI 16(17) PRESENT OUTPUT SIGNAL DRIVE POSITION RI XY

000229

LE XY

Description: Status for voltage feed to solenoid valve operating position. Circuit diagram: Circuit Combi Att group 7.9 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

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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.1 COMBI

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) Circuit diagram: Circuit Combi Att group 7.9 Connection: Function: 7.9.2.3 Control valve lifting jacks Signal value: -

Workshop manual DRF 400–450

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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

Confirm selection with function key for Enter.

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

Connection: from S177/1 to digital in D790-1/K8:7 Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab Signal value: 1

Input signal active.

0

No signal.

SWITCHES, REVERSE Description: Signal from switch hydraulic sliding cab (backward) or switch hydraulic vertically adjustable cab (down).

1(4) X X X

Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000215

DIAG SLID-CAB SWITCHES FORWARD REVERSE OPENED DOORS

Connection: from S177/7 to digital in D790-1/K8:6 Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab Signal value: 1

Input signal active.

0

No signal.

SWITCHES, OPENED DOORS Description: Signal from door contacts, provided that the doors are closed.

1(4) X X X

Circuit diagram: Circuit Lighting group 9.6 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 Function: 9.10.2 Doors Signal value:

VDRF03.02GB

1

Input signal active. Door open.

0

No signal. Doors closed.

Workshop manual DRF 400–450

8 Control system – 8.4.11.2 SLIDING-CAB

155

SLIDING-CAB, menu 2

page –

PRESENT INPUT SIGNAL, LOW SPEED Description: Signal from sensor damping end position, sliding cab or vertically adjustable cab. Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000232

DIAG SLID-CAB 2(4) PRESENT INPUT SIGNAL 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

Input signal active.

0

No signal.

PRESENT INPUT SIGNAL, CAB SPEED (LIFT) Description: Signal from sensor lowered cab (vertically adjustable cab). Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000232

DIAG SLID-CAB 2(4) PRESENT INPUT SIGNAL 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

Input signal active.

0

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

Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 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

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.

Workshop manual DRF 400–450

VDRF03.02GB

156

8 Control system – 8.4.11.2 SLIDING-CAB

OUTPUT FORWARD, REQUIRED VALUE Description: Reference value for control current to control valve option, solenoid valve sliding cab forward.

3(4) XY XXX XXX

Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000233

DIAG SLID-CAB OUTPUT FORWARD REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal reference value out from D797-O/K1:16 to Y6016/2 Function: 9.10.4.4 Control valve option frame Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT FORWARD, FEEDBACK Description: Present control current to control valve option, solenoid valve sliding cab forward.

3(4) XY XXX XXX

Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000233

DIAG SLID-CAB OUTPUT FORWARD REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal actual value out from D797-O/K1:16 to Y6016/2 Function: 9.10.4.4 Control valve option frame 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

Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000234

DIAG SLID-CAB OUTPUT REVERSE REFERENCE REQUIRED VALUE FEEDBACK

Connection: digital out from D797-O/K1:3 to B6017/1 Function: 9.10.4.4 Control valve option frame 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.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.2 SLIDING-CAB

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

Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000234

DIAG SLID-CAB OUTPUT REVERSE REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal reference value out from D797-O/K1:17 to Y6017/2 Function: 9.10.4.4 Control valve option frame Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT REVERSE, FEEDBACK Description: Present control current to control valve option, solenoid valve sliding cab backward.

4(4) XY XXX XXX

Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10 000234

DIAG SLID-CAB OUTPUT REVERSE REFERENCE REQUIRED VALUE FEEDBACK

Connection: output signal actual value out from D797-O/K1:17 to Y6017/2 Function: 9.10.4.4 Control valve option frame Signal value: XXX = Measured value in mA.

Workshop manual DRF 400–450

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

Confirm selection with function key for Enter.

SWITCHES, UP Description: Signal from switch support jacks (up).

1(4) X X

Circuit diagram: Circuit Hyd support jacks group 7.10 Connection: from S1013/1 to digital in D790-1/K8:9 000213

DIAG S-JACKS SWITCHES UP DOWN

Function: 7.10.1 Support jacks Signal value: 1

Input signal active.

0

No signal.

SWITCHES, DOWN Description: Signal from switch support jacks (down).

1(4) X X

Circuit diagram: Circuit Hyd support jacks group 7.10 Connection: from S1013/7 to digital in D790-1/K8:8 000213

DIAG S-JACKS SWITCHES UP DOWN

Function: 7.10.1 Support jacks Signal value: 1

Input signal active.

0

No signal.

SUPPORT-JACKS, menu 2

page –

PRESENT INPUT SIGNALS, UP Description: Signal from sensor support jacks up.

DIAG S-JACKS 2(4) PRESENT INPUT SIGNALS

Circuit diagram: Circuit Hyd support jacks group 7.10 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

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.11.3 SUPPORT-JACKS

159

PRESENT INPUT SIGNALS, DOWN Description: Signal from sensor support jacks down.

DIAG S-JACKS 2(4) PRESENT INPUT SIGNALS

Circuit diagram: Circuit Hyd support jacks group 7.10

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

Input signal active.

0

No signal.

SUPPORT-JACKS, menu 3

page –

OUTPUT VALVE S-J UP Description: Voltage feed to control valve option frame, solenoid valve support jacks up.

3(4) XY XY

Circuit diagram: Circuit Hyd support jacks group 7.10 000237

DIAG S-JACKS OUTPUT VALVE S-J UP S-J DOWN

Connection: digital out from D797-O/K1:30 to B6063/1 Function: 7.10.1.2 Control valve option frame 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.

Workshop manual DRF 400–450

VDRF03.02GB

160

8 Control system – 8.4.11.3 SUPPORT-JACKS

OUTPUT VALVE S-J DOWN Description: Voltage feed to control valve option frame, solenoid valve support jacks down.

3(4) XY XY

Circuit diagram: Circuit Hyd support jacks group 7.10 000237

DIAG S-JACKS OUTPUT VALVE S-J UP S-J DOWN

Connection: digital out from D797-O/K1:31 to B6064/1 Function: 7.10.1.2 Control valve option frame 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.

SUPPORT-JACKS, menu 4

page –

INDICATION LAMP, DOWN

DOWN

Description: The status of voltage feed to indicator light support jacks down.

4(4)

Circuit diagram: Circuit Hyd support jacks group 7.10

XY

000238

DIAG S-JACKS INDICATOR LAMP

Connection: digital out from D790-1/K7:11 to H574/1 Function: 7.10.1 Support jacks 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.

VDRF03.02GB

Workshop manual DRF 400–450

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

Confirm selection with function key for Enter.

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) PRESENT INPUT SIGNAL 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 Signal value: X.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, SIGNAL 2 Description: Signal from mini-wheel (signal 2). (Only applies to miniwheel) 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) PRESENT INPUT SIGNAL 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 Function: 5.2 Power assisted system Signal value: X.XXV = 0.50 - 4.50 V

EL-STEERING, menu 2

page –

SWITCHES, ON/OFF Description: Signal from switch mini-wheel/steering lever.

2(5) X X X

Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 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 Function: 5.2 Power assisted system Signal value: 1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

VDRF03.02GB

162

8 Control system – 8.4.11.4 EL-STEERING

SWITCHES, FORWARD Description: Signal from mini-wheel or steering lever (travel direction selector forward).

2(5) X X X

Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 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 Function: 5.2 Power assisted system Signal value: 1

Input signal active.

0

No signal.

SWITCHES, REVERSE Description: Signal from mini-wheel or steering lever (travel direction selector reverse).

2(5) X X X

Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 000240

DIAG STEERING SWITCHES ON/OFF FORWARD REVERSE

Connection: Top lift attachment: signal from S160-2/7 to digital in D790-1/K9:3 Combi attachment: signal from S160-2/7 to digital in D790-3/ K1:13 Function: 5.2 Power assisted system Signal value:

VDRF03.02GB

1

Input signal active.

0

No signal.

Workshop manual DRF 400–450

8 Control system – 8.4.11.4 EL-STEERING

163

EL-STEERING, menu 3

page –

PRESENT INPUT SIGNAL, HORN Description: Signal from mini-wheel or steering lever (audible signal). Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 006882

DIAG S-JACKS 3(X) PRESENT INPUT SIGNAL HORN X STEER.WHEEL CUT OFF X

Connection: Top lift attachment: signal from S149-2/1 to digital in D790-1/ K9:10 Combi attachment: signal from S149-2/1 to digital in D790-3/ K1:41 Function: 5.2 Power assisted system Signal value: 1

Input signal active.

0

No signal.

PRESENT INPUT SIGNAL, STEER.WHEEL CUT OFF Description: Signal from sensor steering angle. Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 006882

DIAG S-JACKS 3(X) PRESENT INPUT SIGNAL 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

Input signal active.

0

No signal.

Workshop manual DRF 400–450

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164

8 Control system – 8.4.11.4 EL-STEERING

EL-STEERING, menu 4

page –

OUTPUT STEERING LEFT, REFERENCE Description: Status for control current to control valve option frame, solenoid valve steering left. Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 000242

DIAG STEERING 4(5) OUTPUT STEERING LEFT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D797-O/K1:4 to Y636L/1 Function: 5.2.10 Control valve option frame 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.

OUTPUT STEERING LEFT, REQUIRED VALUE Description: Reference value for control current to control valve option frame, solenoid valve steering left. Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 000242

DIAG STEERING 4(5) OUTPUT STEERING LEFT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D797-O/K1:18 to Y636L/2 Function: 5.2.10 Control valve option frame Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT STEERING LEFT, FEEDBACK Description: Present control current to control valve option frame, solenoid valve steering left. Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 000242

DIAG STEERING 4(5) OUTPUT STEERING LEFT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal, reference value out from D797-0/K1:18 to Y636L/2 Function: 5.2.10 Control valve option frame Signal value: XXX = Current value: in mA for control of solenoid valve.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.4.11.4 EL-STEERING

165

EL-STEERING, menu 5

page –

OUTPUT STEERING RIGHT, REFERENCE Description: Status for control current to control valve option frame, solenoid valve steering left. Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 000243

DIAG STEERING 5(5) OUTPUT STEERING RIGHT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D797-O/K1:5 to Y636R/1 Function: 5.2.10 Control valve option frame 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.

OUTPUT STEERING RIGHT, REQUIRED VALUE Description: Reference value for control current to control valve option frame, solenoid valve steering left. Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 000243

DIAG STEERING 5(5) OUTPUT STEERING RIGHT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D797-O/K1:19 to Y636R/2 Function: 5.2.10 Control valve option frame Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT STEERING RIGHT, FEEDBACK Description: Present control current to control valve option frame, solenoid valve steering left. Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit Steering lever/mini wheel and Combi att. group 5.2 000243

DIAG STEERING 5(5) OUTPUT STEERING RIGHT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: output signal reference value out from D797-O/K1:19 to Y636R/2 Function: 5.2.10 Control valve option frame Signal value: XXX = Current value: in mA for control of solenoid valve.

Workshop manual DRF 400–450

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166

8 Control system – 8.4.13 RMI

8.4.13

RMI

RMI, description

page –

This group covers RMI (Remote Machine Interface) function. Confirm selection with function key for Enter. 007442

DIAGNOSIS CAN/POWER LIGHTS CAB 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

Workshop manual DRF 400–450

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 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%.

SIGNAL QUALITY, WLAN

page –

Description: Signal strength of WLAN signal through receiver in the RMI interface. 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%.

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 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%.

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 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%.

Workshop manual DRF 400–450

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 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 = 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 Circuit diagram: Circuit RMI group 8.2 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 –

Description: Internal error code for the RMI interface Circuit diagram: Circuit RMI group 8.2 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

ACT.ERR

page –

Description: Internal error code for the RMI interface Circuit diagram: Circuit RMI group 8.2 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

VDRF03.02GB

Workshop manual DRF 400–450

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 –

2

1

9(10) XXXmA XXXmA

3

000058

4

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.

Workshop manual DRF 400–450

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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

INIT DRIVE-TRAIN, menu 1 page 191

2 Transmission, speed limit shifting forward - reverse

INIT DRIVE-TRAIN, menu 2 page 191

2 Transmission, engine speed limit shifting forward - reverse

INIT DRIVE-TRAIN, menu 3 page 192

2 Transmission, engine speed limit shifting neutral - gear

INIT DRIVE-TRAIN, menu 4 page 192

2 Transmission, engine speed limit kickdown to 1st

INIT DRIVE-TRAIN, menu 5 page 193

2 Transmission, speed limit declutch

INIT DRIVE-TRAIN, menu 6 page 193

2 Transmission, speed limitation (gear lock-out)

INIT DRIVE-TRAIN, menu 10 page 194

2 Transmission, automatic engine speed reduction for shift forward - reverse

INIT DRIVE-TRAIN, menu 12 page 195

5.2 Power assisted system (product option joystick control or mini-wheel), lever response

VDRF03.02GB

Workshop manual DRF 400–450

INIT STEERING, menu 1 page 186

8 Control system – 8.5.1 Initiation

171

Function

Menu

5.2 Power assisted system (product option joystick control or mini-wheel), speed dependent

INIT STEERING, menu 2 page 187 INIT STEERING, menu 3 page 187 INIT STEERING, menu 4 page 188 INIT STEERING, menu 5 page 188 INIT STEERING, menu 6 page 189

5.2 Power assisted system (product option joystick control or mini-wheel), steering angle right

INIT STEERING, menu 7 page 189

5.2 Power assisted system (product option joystick control or mini-wheel), steering angle left

INIT STEERING, menu 9 page 190

7.2 Lifting/lowering, boom up

INIT BOOM, menu 1 page 173

INIT STEERING, menu 8 page 189

INIT STEERING, menu 10 page 190

INIT BOOM, menu 2 page 173 7.2 Lifting/lowering, boom down

INIT BOOM, menu 3 page 174

Note: The current value is for unladen machines. When loaded, the current value is controlled by the limited lowering speed.

INIT BOOM, menu 4 page 174

7.2 Lifting/lowering, lift speed during operation

INIT BOOM, menu 9 page 176

7.2 Lifting/lowering, damping at container (top lift)

INIT ATTACH, menu 15 page 182

7.2 Lifting/lowering, damping at container (bottom lift)

INIT ATTACH, menu 16 page 182

7.3 Extension, boom out

INIT BOOM, menu 5 page 174 INIT BOOM, menu 6 page 175

7.3 Extension, boom in

INIT BOOM, menu 7 page 175

Note: The current value is for unladen machines. When loaded, the current value is controlled by the limited lowering speed.

INIT BOOM, menu 8 page 175

7.5 Spreading out

INIT ATTACH, menu 9 page 180 INIT ATTACH, menu 10 page 180 INIT ATTACH, menu 11 page 180

7.5 Spreading in

INIT ATTACH, menu 12 page 181 INIT ATTACH, menu 13 page 181 INIT ATTACH, menu 14 page 181

7.6 Rotation, clockwise

INIT ATTACH, menu 1 page 177 INIT ATTACH, menu 2 page 177

7.6 Rotation, anticlockwise

INIT ATTACH, menu 3 page 178 INIT ATTACH, menu 4 page 178

7.7 Tilt

INIT ATTACH, menu 5 page 178 INIT ATTACH, menu 6 page 179

7.8 Levelling

INIT ATTACH, menu 7 page 179 INIT ATTACH, menu 8 page 179

8.2.3 Load centre limitation

INIT BOOM, menu 10 page 176

Workshop manual DRF 400–450

VDRF03.02GB

172

8 Control system – 8.5.1 Initiation

Function

Menu

8.2.4 Height limitation

INIT BOOM, menu 11 page 176

9.10.4 Sliding cab, forward

INIT SLID-CAB, menu 1 page 183

9.10.5 Vertically adjustable cab, up

INIT SLID-CAB, menu 2 page 184 INIT SLID-CAB, menu 3 page 184

9.10.4 Sliding cab, backward

INIT SLID-CAB, menu 4 page 184

9.10.5 Vertically adjustable cab, down

INIT SLID-CAB, menu 5 page 185 INIT SLID-CAB, menu 6 page 185

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. Code is obtained from Cargotec Support.

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

Workshop manual DRF 400–450

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 SLIDING-CAB STEERING 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 Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps.

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. Function: 7.2.5 Control valve lift, lower and extension 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. Function: 7.2.5 Control valve lift, lower and extension Component: Solenoid valve, lift (Y6005) Signal value: XXXmA = 0 - 999 mA

Workshop manual DRF 400–450

VDRF03.02GB

174

8 Control system – 8.5.1.1 BOOM

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE indicates stored value for start current. Function: 7.2.5 Control valve lift, lower and extension Component: Solenoid valve, lower (Y6004) Signal value: XXXmA = 0 - 999 mA

INIT BOOM, menu 4

page –

END CURRENT, LOWER

4(11) XXXmA XXXmA

Description: Control current at full lever actuation for the activation of the solenoid valve for lower (Y6004). 005045

INIT BOOM END CURRENT LOWER STORED VALUE PRESENT VALUE

PRESENT VALUE: Indicates the current value for max. current. Adjust the value with the plus and minus keys. 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. Function: 7.2.5 Control valve lift, lower and extension Component: Solenoid valve, lower (Y6004) Signal value: XXXmA = 0 - 999 mA

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve lift, lower and extension Component: solenoid valve boom out (Y6006) Signal value: XXXmA = 0 - 999 mA

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.5.1.1 BOOM

175

INIT BOOM, menu 6

page –

END CURRENT, BOOM OUT

6(11) XXXmA XXXmA

Description: Control current at full lever actuation for the activation of the solenoid valve for boom out (Y6006). 005047

INIT BOOM END CURRENT BOOM OUT 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. Function: 7.2.5 Control valve lift, lower and extension Component: solenoid valve boom out (Y6006) Signal value: XXXmA = 0 - 999 mA

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve lift, lower and extension Component: solenoid valve boom in (Y6007) Signal value: XXXmA = 0 - 999 mA

INIT BOOM, menu 8

page –

END CURRENT, BOOM IN

8(11) XXXmA XXXmA

Description: Control current at full lever actuation for the activation of the solenoid valve for boom in (Y6007). 005049

INIT BOOM END CURRENT BOOM IN 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. Function: 7.2.5 Control valve lift, lower and extension Component: solenoid valve boom in (Y6007) Signal value: XXXmA = 0 - 999 mA

Workshop manual DRF 400–450

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176

8 Control system – 8.5.1.1 BOOM

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 the Enter key. Go to the next menu with the arrow keys. Exit initiation 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 axle’s centre.

NOTE On machines with vertically adjustable cab, a load centre less than the cab’s frontmost point cannot be selected. PRESENT VALUE: Indicates the current value for load centre. 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 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 boom’s highest point. PRESENT VALUE: Indicates the current value for height limitation. 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 height limitation. Function: 8.2.4 Height limitation Component: Signal Value: XX.XX = height limitation in metres.

VDRF03.02GB

Workshop manual DRF 400–450

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 SLIDING-CAB STEERING 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 Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps.

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.6.3 Control valve attachment Component: Solenoid valve rotation clockwise (Y6008) Signal value: XXXmA = 0 - 999 mA

INIT ATTACH, menu 2

page –

END CURRENT, ROTATION CW

2(14) XXXmA XXXmA

Description: Control current at full lever actuation for the activation of the solenoid valve for rotation anticlockwise (Y6009). 005092

INIT ATTACH END CURRENT ROTATION CW 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. Function: 7.6.3 Control valve attachment Component: Solenoid valve anticlockwise (Y6009) Signal value: XXXmA = 0 - 999 mA

Workshop manual DRF 400–450

VDRF03.02GB

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8 Control system – 8.5.1.2 ATTACHMENT

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.6.3 Control valve attachment Component: Solenoid valve rotation anticlockwise (Y6009) Signal value: XXXmA = 0 - 999 mA

INIT ATTACH, menu 4

page –

END CURRENT, ROTATION CCW

4(14) XXXmA XXXmA

Description: Control current at full lever actuation for the activation of the solenoid valve for rotation anticlockwise (Y6009). 005094

INIT ATTACH END CURRENT ROTATION CCW 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. Function: 7.6.3 Control valve attachment Component: Solenoid valve anticlockwise (Y6009) Signal value: XXXmA = 0 - 999 mA

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.7.5 Control valve attachment Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt out (Y6011) Signal value: XXXmA = 0 - 999 mA

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.5.1.2 ATTACHMENT

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). 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. Function: 7.7.5 Control valve attachment Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt out (Y6011) Signal value: XXXmA = 0 - 999 mA

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.8.3 Control valve attachment Component: Solenoid valve for levelling right (Y6035), Solenoid valve for levelling left (Y6036) Signal value: XXXmA = 0 - 999 mA

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). 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. Function: 7.8.3 Control valve attachment Component: Solenoid valve for levelling right (Y6035), Solenoid valve for levelling left (Y6036) Signal value: XXXmA = 0 - 999 mA

Workshop manual DRF 400–450

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8 Control system – 8.5.1.2 ATTACHMENT

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). 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.

I [mA] 1

STORED VALUE indicates stored value for max. current.

2 t [s]

005517

Function: 7.5.3 Control valve attachment

3

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 SPREADER OUT, 20'-40' STORED VALUE XXXmA PRESENT VALUE XXXmA

Description: Control current at full lever actuation for activation of solenoid valve for spreading out (Y6018). 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.

I [mA] 1

STORED VALUE indicates stored value for max. current.

2 t [s]

005518

Function: 7.5.3 Control valve attachment

3

Component: Solenoid valve for spreading out (Y6018) Signal value: XXXmA = 0 - 999 mA

1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

INIT ATTACH, menu 11

page –

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

INIT ATTACH 11(X) DAMP (PROC) SPREADER OUT, 20'-40' STORED VALUE XX PRESENT VALUE XX

Description: Control current to solenoid valve for spreading out (Y6018) during damping, when damping is approaching 40’. 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.

I [mA] 1

STORED VALUE: indicates stored value in percent.

2 t [s] 1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

VDRF03.02GB

005519

Function: 7.8.3 Control valve attachment

3

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

Workshop manual DRF 400–450

8 Control system – 8.5.1.2 ATTACHMENT

181

INIT ATTACH, menu 12

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). 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.

I [mA] 1

STORED VALUE indicates stored value for max. current.

2 3 t [s]

005520

Function: 7.5.3 Control valve attachment Component: Solenoid valve for spreading in (6019) Signal value: XXXmA = 0 - 999 mA.

1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

INIT ATTACH, menu 13

page –

END CURRENT, SPREADER IN 40'-20'

INIT ATTACH 13(X) END CURRENT SPREADER IN, 40'-20' STORED VALUE XXXmA PRESENT VALUE XXXmA

Description: Control current at full lever actuation for activation of solenoid valve for spreading in (Y6019). 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.

I [mA] 1

STORED VALUE indicates stored value for max. current.

2 3 t [s]

005521

Function: 7.5.3 Control valve attachment Component: Solenoid valve for spreading in (Y6019) Signal value: XXXmA = 0 - 999 mA

1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

INIT ATTACH, menu 14

page –

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

INIT ATTACH 14(X) DAMP (PROC) SPREADER IN, 40'-20' STORED VALUE XX PRESENT VALUE XX

Description: Control current to solenoid valve for spreading in (Y6019) during damping, when damping is approaching 20’. 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.

I [mA] 1

STORED VALUE: indicates stored value in percent.

2 t [s] 1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

005522

Function: 7.8.3 Control valve attachment

3

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

Workshop manual DRF 400–450

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8 Control system – 8.5.1.2 ATTACHMENT

INIT ATTACH, menu 15

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 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 the distance. Function: Component: Signal value: XXXX = distance in cm.

INIT ATTACH, menu 16

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 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 the distance. Function: Component: Signal value: XXXX = distance in cm

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.5.1.3 SLIDING-CAB

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 SLIDING-CAB STEERING 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 Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps.

INIT SLID-CAB, menu 1

page –

START CURRENT, 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

1

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.

2

STORED VALUE: indicates stored value for start current.

3 t [s] 1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

001698

I [mA]

Function: 9.10.4.3 Control valve option frame Component: Solenoid valve sliding cab forward (Y6016) Signal value: XXXmA = 0 - 999 mA

Workshop manual DRF 400–450

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8 Control system – 8.5.1.3 SLIDING-CAB

INIT SLID-CAB, menu 2

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

1

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.

2

STORED VALUE indicates stored value for max. current.

3 t [s]

001787

I [mA]

1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

Function: 9.10.4.3 Control valve option frame Component: Solenoid valve sliding cab forward (Y6016) Signal value: XXXmA = 0 - 999 mA

INIT SLID-CAB, menu 3

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

1

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.

2

STORED VALUE: indicates stored value for start current.

3 t [s]

001850

I [mA]

1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

Function: 9.10.4.3 Control valve option frame Component: Solenoid valve sliding cab forward (Y6016) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e., start current.

INIT SLID-CAB, menu 4

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

1

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.

2

STORED VALUE: indicates stored value for start current.

3 t [s] 1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

VDRF03.02GB

003001

I [mA]

Function: 9.10.4.3 Control valve option frame Component: Solenoid valve sliding cab backward (Y6017) Signal value: XXXmA = 0 - 999 mA

Workshop manual DRF 400–450

8 Control system – 8.5.1.3 SLIDING-CAB

185

INIT SLID-CAB, menu 5

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

1

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.

2

STORED VALUE indicates stored value for max. current.

3 t [s]

003022

I [mA]

1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

Function: 9.10.4.3 Control valve option frame Component: Solenoid valve sliding cab backward (Y6017) Signal value: XXXmA = 0 - 999 mA

INIT SLID-CAB, menu 6

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

1

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.

2

STORED VALUE: indicates stored value for start current.

3 t [s] 1. Max. current (END CURRENT) 2. Damping (PROC DAMPING) 3. Start current (START CURRENT)

003093

I [mA]

Function: 9.10.4.3 Control valve option frame Component: Solenoid valve sliding cab backward (Y6017) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e., start current.

Workshop manual DRF 400–450

VDRF03.02GB

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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 SLIDING-CAB STEERING DRIVE-TRAIN

The settings affect the functions joystick control or mini-wheel. Adjustment can impair functionality. If in doubt, contact Cargotec Service.

NOTE Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps.

INIT 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.

0

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

X

STORED VALUE: indicates saved curve. Function: 5.2 Power assisted system (product option joystick control or mini-wheel) Component: Signal value: XX = 0-31.

Workshop manual DRF 400–450

8 Control system – 8.5.1.4 STEERING

187

INIT STEERING, menu 2

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 machine’s 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

Function: 5.2 Power assisted system (product option joystick control 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 = speed setting for break point 2 BP3 = speed setting for break point 3 %BP2 = percent of control current to solenoid valve at BP2 %BP3 = percent of control current to solenoid valve at BP3

Component: Signal value: XX.X = speed for BP1 in km/h.

INIT STEERING, menu 3

page –

BREAK POINT BP2

INIT STEERING BRAKE POINT BP2 (kph) STORED VALUE PRESENT VALUE

3(10)

Description: Speed for break point 2. Break points are used to adapt the steering angle to the machine’s 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 2. 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 2.

% BP2 % BP3 V [kph] BP1

BP2

BP3

003132

Function: 5.2 Power assisted system (product option joystick control 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 = speed setting for break point 2 BP3 = speed setting for break point 3 %BP2 = percent of control current to solenoid valve at BP2 %BP3 = percent of control current to solenoid valve at BP3

Component: Signal value: XX.X = speed for BP2 in km/h.

Workshop manual DRF 400–450

VDRF03.02GB

188

8 Control system – 8.5.1.4 STEERING

INIT STEERING, menu 4

page –

BREAK POINT BP3

INIT STEERING BRAKE POINT BP3 (kph) STORED VALUE PRESENT VALUE

4(10)

Description: Speed for break point 3. Break points are used to adapt the steering angle to the machine’s 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 3. 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%

STORED VALUE: indicates saved speed for break point 3.

% BP2 % BP3 V [kph] BP1

BP2

BP3

003133

Function: 5.2 Power assisted system (product option joystick control 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 = speed setting for break point 2 BP3 = speed setting for break point 3 %BP2 = percent of control current to solenoid valve at BP2 %BP3 = percent of control current to solenoid valve at BP3

Component: Signal value: XX.X = speed for BP3 in km/h.

INIT STEERING, menu 5

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 the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key.

I [mA] 100% % BP2 % BP3 V [kph] BP1

BP2

BP3

003134

STORED VALUE: indicates stored value for the reduction.

I [mA] = control current to solenoid valve V [kph] = machine speed in km/h BP1 = speed setting for break point 1 BP2 = speed setting for break point 2 BP3 = speed setting for break point 3 %BP2 = percent of control current to solenoid valve at BP2 %BP3 = percent of control current to solenoid valve at BP3

VDRF03.02GB

Function: 5.2 Power assisted system (product option joystick control 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.

Workshop manual DRF 400–450

8 Control system – 8.5.1.4 STEERING

189

INIT STEERING, menu 6

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 the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key.

I [mA] 100% % BP2 % BP3 V [kph] BP1

BP2

BP3

003135

STORED VALUE: indicates stored value for the reduction.

I [mA] = control current to solenoid valve V [kph] = machine speed in km/h BP1 = speed setting for break point 1 BP2 = speed setting for break point 2 BP3 = speed setting for break point 3 %BP2 = percent of control current to solenoid valve at BP2 %BP3 = percent of control current to solenoid valve at BP3

Function: 5.2 Power assisted system (product option joystick control 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.

INIT STEERING, menu 7

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R key. STORED VALUE: indicates stored value for start current. Function: 5.2.10 Control valve, lever steering/mini wheel Component: Solenoid valve for steering right (Y636R) Signal value: XXXmA = 0 - 999 mA

INIT STEERING, menu 8

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

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. Function: 5.2.10 Control valve, lever steering/mini wheel Component: Solenoid valve for steering right (Y636R) Signal value: XXXmA = 0 - 999 mA

Workshop manual DRF 400–450

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190

8 Control system – 8.5.1.4 STEERING

INIT STEERING, menu 9

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

PRESENT VALUE: Indicates the current value for the start current. Adjust the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 5.2.10 Control valve, lever steering/mini wheel Component: Solenoid valve for steering left (Y636L) Signal value: XXXmA = 0 - 999 mA

INIT STEERING, menu 10

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

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. Function: 5.2.10 Control valve, lever steering/mini wheel Component: Solenoid valve for steering left (Y636L) Signal value: XXXmA = 0 - 999 mA

VDRF03.02GB

Workshop manual DRF 400–450

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 SLIDING-CAB STEERING DRIVE-TRAIN

Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps. The machine must be stationary with applied parking brake to 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 with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = 1= yes, XXX = 0 = no

INIT DRIVE-TRAIN, menu 2

page –

VEHICLE SPEED F-R

INIT DRIVE-TRN 2(12) VEHICLE SPEED F-R XXX XXX

005051

STORED VALUE PRESENT VALUE

Description: Setting of highest permitted speed for shifting between forward and reverse. PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = speed in km/h

Workshop manual DRF 400–450

VDRF03.02GB

192

8 Control system – 8.5.1.5 DRIVETRAIN

INIT DRIVE-TRAIN, menu 3

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 engine’s idle rpm, shifting will not be allowed. PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = engine speed (rpm)

INIT DRIVE-TRAIN, menu 4

page –

ENGINE SPEED N-DIR

INIT DRIVE-TRN 4(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. PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = engine speed (rpm)

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.5.1.5 DRIVETRAIN

193

INIT DRIVE-TRAIN, menu 5

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. PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = speed (km/h)

INIT DRIVE-TRAIN, menu 6

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

PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = speed (km/h)

page –

INIT DRIVE-TRAIN, menu 7 Not used.

page –

INIT DRIVE-TRAIN, menu 8 Not used.

Workshop manual DRF 400–450

VDRF03.02GB

194

8 Control system – 8.5.1.5 DRIVETRAIN

INIT DRIVE-TRAIN, menu 9

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

PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = speed (km/h)

INIT DRIVE-TRAIN, menu 10

page –

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). PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = gear

INIT DRIVE-TRAIN, menu 11

page –

OPTION ENGINE SHUT DOWN

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

PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 1 Engine Component: Signal value: XXX = time in seconds before engine shutdown.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.5.1.5 DRIVETRAIN

195

INIT DRIVE-TRAIN, menu 12

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. PRESENT VALUE: Indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: X = 1, activated X = 0, deactivated

Workshop manual DRF 400–450

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 Calibration does not need to be performed in one process but each step can be performed separately, independently of other steps.

VDRF03.02GB

Workshop manual DRF 400–450

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):

2

5

CALIBR SCALE 3(7) BOOM FULLY RETRACTED

4

STORED VALUE PRESENT VALUE

X.XXV X.XXV

3

000063

1

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. Code is obtained from Cargotec Support.

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.

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).

Workshop manual DRF 400–450

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.

3 State code for calibration. Code is obtained from Cargotec Support.

000060

1 23 4 5

NOTE The code determines which service menu is activated (Diagnostic test, Initiation or Calibration). 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

Workshop manual DRF 400–450

8 Control system – 8.5.2.1 Calibrate SCALE

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. 13 Scroll to CALIBR SCALE, menu 9. 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' ". 15 Wait approximately five seconds to stabilise the pressure. 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 17 Scroll to CALIBR SCALE, menu 10.

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.

Workshop manual DRF 400–450

VDRF03.02GB

200

8 Control system – 8.5.2.1 Calibrate SCALE

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.

4 State code for calibration. Code is obtained from Cargotec Support.

000060

1 23 4 5

NOTE The code determines which service menu is activated (Diagnostic test, Initiation or Calibration). 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 boom’s 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

9 Scroll to CALIBR SCALE, menu 2.

CALIBR SCALE 2(x) MAXIMUM BOOM ANGLE

10 Lift the boom to its highest angle.

X.XXV X.XXV

011330

11 Save the setting with ENTER.

STORED VALUE PRESENT VALUE

12 Scroll to CALIBR SCALE, menu 3.

CALIBR SCALE 3(X) BOOM FULLY RETRACTED

13 Retract the boom completely.

VDRF03.02GB

X.XXV X.XXV

011331

14 Save the setting with ENTER.

STORED VALUE PRESENT VALUE

Workshop manual DRF 400–450

8 Control system – 8.5.2.1 Calibrate SCALE

201

15 Scroll to CALIBR SCALE, menu 4.

CALIBR SCALE 4(X) BOOM FULLY EXTENDED

16 Extend the boom completely.

X.XXV X.XXV

011332

17 Save the setting with ENTER.

STORED VALUE PRESENT VALUE

18 Scroll to CALIBR SCALE, menu 5. 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

21 Wait approximately five seconds to stabilise the pressure. 22 Save the setting with ENTER. 23 Scroll to CALIBR SCALE, menu 6. 24 Extend the boom completely. 25 Wait approximately five seconds to stabilise the pressure. 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 27 Scroll to CALIBR SCALE, menu 7. 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.

Workshop manual DRF 400–450

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8 Control system – 8.5.2.2 Calibrate STEERING

8.5.2.2

Calibrate STEERING

Lever steering, calibration

page –

NOTE Calibration does not need to be performed in one process but each step can be performed separately, independently of other steps. 1 Start key in operating position.

CALIBR STEERING, menu 1 2 Go into the calibration menus and select CALIBR STEERING, 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.

CALIBR STEERING, menu 2 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). 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 6 Move steering lever to required position for max. angle left. 7 Store the position with function key for Enter.

VDRF03.02GB

Workshop manual DRF 400–450

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN

203

CALIBR STEERING, menu 3 8 STEERING LEVER RIGHT POSITION Description: Setting for position for max. angle right on lever steering control (R825). 000077

CALIBR STEERING 3(3) STEERING LEVER RIGHT POSITION CALIBR VALUE X.XXV PRESENT VALUE X.XXV

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 9 Move steering lever to required position for max. angle right. 10 Store the position with function key for Enter.

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 accelerator’s 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. 4 Store the position with function key for Enter.

DRIVE-TRAIN, menu 2 5 ACCELERATOR, THE PEDAL TO FLOOR Description: Setting of full-throttle position of Accelerator pedal (R690). 000080

CALIBR DRIVE-TRN 2(4) 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. 7 Store the position with function key for Enter.

Workshop manual DRF 400–450

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204

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN

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.

3 State code for calibration. Code is obtained from Cargotec Support.

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

Workshop manual DRF 400–450

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN

205

7 Select DRIVE-TRAIN, menu 3. GEARBOX TUNING Description: Calibration of transmission couplings. 000081

CALIBR DRIVE-TRN 3(4) 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.

Workshop manual DRF 400–450

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206

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN

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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories

1

9 Frame, body, cab and accessories

Table of Contents 9 Frame, body, cab and accessories mm mm mm mm mm mm

9 Frame, body, cab and accessories............................................................... 5 9.1 Controls and instruments ........................................................................... 5 9.1.1 Gear selector and multi-function lever ................................................. 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

Workshop manual DRF 400–450

VDRF03.02GB

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9 Frame, body, cab and accessories

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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories

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

Workshop manual DRF 400–450

3

117 117 118 118 119 121 122 122 123

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9 Frame, body, cab and accessories

Workshop manual DRF 400–450

9 Frame, body, cab and accessories

5

9 Frame, body, cab and accessories

mm mm mm mm mm mm

9.1

Controls and instruments

Controls and instruments, overview

page –

Overview

1

2

3

4

5

11

10

15

A

13

12

9

8

7

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 Driver’s 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

Workshop manual DRF 400–450

VDRF03.02GB

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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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.1 Controls and instruments

32

33

35

34

7

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

Workshop manual DRF 400–450

VDRF03.02GB

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9 Frame, body, cab and accessories – 9.1 Controls and instruments

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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.1 Controls and instruments

9

Operating menus, overview

1

2

3

4

12

5

11

6

9

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

8

7

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

Workshop manual DRF 400–450

VDRF03.02GB

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9 Frame, body, cab and accessories – 9.1 Controls and instruments

Event menus overview

1

2

3

4

5

6

14

7

13

8

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

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Workshop manual DRF 400–450

006734

15

9 Frame, body, cab and accessories – 9.1 Controls and instruments

page –

11

Switch, replacement

NOTE The instructions apply to switches in general. 1 Machine in service position, see section B Safety. 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.

Workshop manual DRF 400–450

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9 Frame, body, cab and accessories – 9.1.1 Gear selector and multi-function lever

9.1.1

Gear selector and multi-function lever

Gear and multi-function lever, description

page –

2 3

The following functions are handled by the gear and multi-function lever (position 2).

1

000338

0

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. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.3.2 CAB, 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

A

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). The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.3.5 CAB, menu 5.

Workshop manual DRF 400–450

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 1 Machine in service position, see section B Safety. 2 Remove the steering wheel and open the steering wheel panel.

3 Detach the direction indicator wiring harness. 4 Press together the clips on the direction indicator and detach it from the steering wheel panel. 5 Replace the direction indicator, fitting it in the reverse order.

Workshop manual DRF 400–450

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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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.3 Seat

9.3

15

Seat

Seat, general

page –

There are three versions of operator’s 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 seat’s function is to give the operator a good sitting position and contribute to a good work environment. The cab’s seat has several adjustment possibilities and meets high comfort standards.

1

2

The seat has the following equipment:

3

4

•

mechanical adjustment

•

right armrest

•

seat belt (option until model year 2007)

•

left armrest

•

seat heating

•

head restraint

8

6 7

006825

5

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

Workshop manual DRF 400–450

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9 Frame, body, cab and accessories – 9.3 Seat

Seat, description (product alternative BE-GE 9120)

page –

1

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 operator’s weight. Air suspension is supplied by a special compressor installed on the underside of the cab.

2 3

The seat’s function is to give the operator a good sitting position and contribute to a good work environment. The cab’s seat has several adjustment possibilities and meets high comfort standards.

4

The seat has the following equipment:

8

6 7

Controls BE-GE 9120 1. Lumbar support adjustment 2. Right armrest adjustment

006826

5

•

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 8. Front/rear adjustment

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.3 Seat

17

Seat, description (product alternative Isringhausen 6800)

page –

The seat’s function is to give the operator a good sitting position and contribute to a good work environment. The cab’s seat has several adjustment possibilities and meets high comfort standards. 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

9

34 8 2

567

004691

10

Controls, Isringhausen 6800 1. Front/rear adjustment 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 10. Lumbar support adjustment 11. Armrest

Workshop manual DRF 400–450

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page –

9 Frame, body, cab and accessories – 9.3 Seat

Seat, changing 1 Machine in service position, see section B Safety. 2 Slide back the seat to its rear position, remove the front attaching bolts.

3 Slide the seat to its front position, remove the rear attaching bolts. 4 Disconnect the seat’s connectors from the machine’s cabling. 5 Remove the seat. 6 Fit in the reverse order.

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Workshop manual DRF 400–450

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 operator’s 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 –

1 Machine in service position, see section B Safety. 2 Loosen the rubber bellows by removing the plastic clips (position 1). 3 Unhook the upholstery’s rails (position 2) from the seat frame (position 3) and remove the upholstery.

5

2

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 seat’s 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.

3

5 Assemble in reverse order.

006276

1

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 operator’s seat frame. There may also be a heating coil (

).

For location, see Seat, general page 15.

Workshop manual DRF 400–450

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20

9 Frame, body, cab and accessories – 9.3.3 Electric heater

Back cushion, changing (product alternative BE-GE)

page –

1 Machine in service position, see section B Safety. 2 Detach the rubber bellows on the rear of the seat by removing the plastic clips and folding down the rubber bellows. See Seat cushion, changing (product alternative BE-GE) page 19.

3

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.

4

4

If the seat is equipped with 3-point seatbelt. Remove the belt guide (position 3) by removing the cover and the attaching bolt (position 4).

5

5

If the seat is equipped with armrest (position 5). Remove the armrest by removing the attaching bolts (position 6).

6 Place the backrest on the seat and install the attaching bolts (position 1), do not tighten. Then install the attaching bolts for the seatbelt (position 2).

6

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

2

006278

7

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.

8 Fit in the reverse order.

9.3.3 page –

Electric heater

Electric heater, description

The heating coil’s function is to warm the back and seat cushions in the operator’s 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.

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Workshop manual DRF 400–450

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 seat’s bracket and are self-adjusting, that is, they adjust themselves according to the operator’s body weight.

Shock absorber, changing (product alternative BEGE)

page –

1 Machine in service position, see section B Safety.

2

2 Remove the operator’s 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.

1

4 Remove the back cushion; see Back cushion, changing (product alternative BE-GE) page 20.

3

006277

5 Remove the shock absorber’s 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 operator’s seat consists of a seat with rubber bellows and compressor. Air suspension is self-adjusting, that is, adjust automatically to the operator’s 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 operator’s seat and is located inside the seat’s suspension unit.

Isringhausen 6800:

Compressed air-suspended seat The compressor is an external part for the air-suspended operator’s seat that is installed on the cab floor’s underside.

Workshop manual DRF 400–450

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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 operator’s 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:

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•

Mini-wheel

•

Joystick control

Workshop manual DRF 400–450

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 driver’s seat suspension is depressed which indicates for the control and monitoring system that the operator is sitting in the driver’s 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.

1

2

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.

Workshop manual DRF 400–450

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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

F

cab can also be equipped with a climate control system (

The temperature in the cab is thermostat-controlled by the cab control unit (D790-1). The cab temperature is regulated to the set temperature. The temperature can be set between 16 and 28 °C. The unit is operated with controls on the instrument panel.

2 4 D

C

Heating system (EHC)

E

The heating system (EHC) handles heating and ventilation. (The heating system cannot provide cooling.)

E 3

6

).

The heating system uses heat from the engine’s cooling system via a heating coil to heat ambient air. The fan forces the ambient air through the heating coil on through ducts in the cab interior. It is then directed to the windscreen (defroster) or the feet.

A

B

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).

G

1 000762

5

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

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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)

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

25

Heating, ventilation and air conditioning, function description

page –

2

D1

1

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

˚C

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

9

M 10 ˚C

11 006416

8

Pos

Explanation

Signal description

Reference

1

The temperature switch (S139) sends a voltage signal to the cab control unit (D790-1).

Raise: U = 2.0–2.5 V

Controls and instruments, overview page 5

Unaffected: U = 0-0.5 V Lower: U = 4.5-5.0 V

D1: Diagnostic menu, see section 8 Control 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 = 2.0–2.5 V

Controls and instruments, overview page 5

Unaffected: U = 0-0.5 V Lower: U = 4.5-5.0 V

D2: Diagnostic menu, see section 8 Control system , group 8.4.4.5 CLIMATE, menu 5

The air distribution switch (S117) sends a voltage signal to the cab control unit (D790-1).

Scroll up: U = 2.0–2.5 V

Controls and instruments, overview page 5

Unaffected: U = 0 V

D3: Diagnostic menu, see section 8 Control system , group 8.4.4.5 CLIMATE, menu 5

The cab temperature sensor (B775-1) sends the cab control unit (D790-1) a voltage signal proportional to the temperature.

R = 10 kΩ at 25 °C

2

3

4

Scroll down: U = 4.5-5.0V

Workshop manual DRF 400–450

Sensor, cab temperature, description page 56 D4: Diagnostic menu, see section 8 Control system , group 8.4.4.1 CLIMATE, menu 1

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9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

Pos

Explanation

Signal description

Reference

5

The blower fan temperature sensor (B775-2) sends the cab control unit (D790-1) a voltage signal proportional to temperature.

R = 10 kΩ 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 kΩ at 25 °C

7

The cab control unit (D790-1) regulates temperature and air distribution with signals from sensors and controls.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.1 Cab control unit

8

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.

-

-

9

The cab control unit (D790-1) controls the water valve (Y673), which directs hot water to heat exchanger heating.

U = 0.5–4.5 V

Water valve, description page 42

6

D5: Diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE, menu 2

D6: Diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE, menu 2

D9: Diagnostic menu, see section 8 Control system , group 8.4.4.7 CLIMATE, menu 7 and 8.4.4.4 CLIMATE, menu 4

The water valve’s opening (%) is sent back to the cab control unit (D790-1). This gives information for controlling the water valve’s 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.

Checked by control system, error shown with error code.

11

Heat exchanger heat adds heat to the cab air. Heat is transferred from the engine’s cooling system to the cab air.

-

Heat exchanger heat, description page 39

12

The engine control unit (D794) transmits engine temperature in the cooling system on the CAN bus.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.10 Engine control unit

13

The cab control unit (D790-1) controls the recirculation actuator motor (M612) which sets the fresh air or recirculation damper in the required position.

Checked by control system, error shown with error code.

Fresh air filter or recirculation damper, description page 33

The cab control unit (D790-1) controls the fan motor (M657), which increases airflow in the cab.

Checked by control system, error shown with error code.

14

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Workshop manual DRF 400–450

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 D14: Diagnostic menu, see section 8 Control system , group 8.4.4.6 CLIMATE, menu 6

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

27

Pos

Explanation

Signal description

Reference

15

The cab control unit (D790-1) controls the actuator motor (Y672), which sets the air distributor to the required position.

U = 0.5–4.5 V

Air distributor, description page 53 D15: Diagnostic menu, see section 8 Control system , group 8.4.4.8 CLIMATE, menu 8 and 8.4.4.4 CLIMATE, menu 4

The air distributor’s position is sent back to the cab control unit (D790-1). This gives information for controlling the air distributor’s position. 16

The rear frame control unit (D797-R) controls AC compressor engagement.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear

17

The rear frame control unit (D797-R) supplies voltage to the compressor’s 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 evaporator’s 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 kΩ at 25 °C

Sensor temperature refrigerant, description page 51

D17: Diagnostic menu, see section 8 Control system , group 8.4.4.6 CLIMATE, menu 6

D21: Diagnostic menu, see section 8 Control system , group 8.4.4.3 CLIMATE, menu 3

Workshop manual DRF 400–450

D23: Diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE, menu 2.

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28

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

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.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.11 Control unit KIT

26

The KID control unit (D795) shows the heating and ventilation settings in the display.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.12 KID control unit

Heating, ventilation and air conditioning, checking

page –

1 Machine in service position, see section B Safety.

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) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX

4 Select CLIMATE.

000131

Menu 1

5 Check of desired temperature, inside temperature sensor and water valve.

000132

DIAGNOSIS CAN/POWER LIGHTS CAB 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.

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Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

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 circuit’s 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) PRESENT INPUT SIGNAL 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) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV

DRAUGHT VALVE: should work in the range 1.0-4.0 V. The difference between min. and max. should be approx. 1 V. This is checked by changing the air distribution from floor to front 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) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED 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.

Workshop manual DRF 400–450

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9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

Menu 6 10 Checks cab fan (M657), fresh air and recirculation damper (M612) and compressor’s electromagnetic clutch (M645)

.

FAN SPEED: increase and decrease fan speed, value should increase from 0 to 255 in steps.

000137

DIAG CLIMATE 6(8) PRESENT OUTPUT SIGNAL 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 ANTI-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

M

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

31

Menu 8 12 Checks direction selector for air distributor.

DIAG CLIMATE 8(8) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-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

M

Pause heater, description

page –

1

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

3

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)

Workshop manual DRF 400–450

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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.

1

003208

2 1 Fresh air intake, cab

VDRF03.02GB

1.

Fresh air filter

2.

Fresh air and recirculation damper

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper

9.4.2

33

Fresh air and recirculation damper

Fresh air filter or recirculation damper, description

page –

The damper is controlled electrically and controls the air between fully open for fresh air to recirculation of air. The damper is located in the external unit for fresh air intake into the cab. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.6 CLIMATE, menu 6.

1

003208

2 1 Fresh air intake, cab 1.

Fresh air filter

2.

Fresh air and recirculation damper

Workshop manual DRF 400–450

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34

page –

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper

Motor, fresh air filter or recirculation damper, replacement 1 Machine in service position, see section B Safety. 2 Remove the wiper arms.

3 Remove the nuts which hold the wiper motor in the protective plate. 4 Remove the protective plate.

5 Remove the fresh air filter.

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Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper

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.

Workshop manual DRF 400–450

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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. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.6 CLIMATE, menu 6.

003209

1

Fresh air intake, cab 1. Cab fan page –

Cab fan, replacement 1 Machine in service position, see section B Safety. 2 Remove the wiper arms.

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9 Frame, body, cab and accessories – 9.4.3 Cab fan

37

3 Remove the bolts which secure the wiper motor in the protective plate. 4 Remove the protective plate.

5 Detach the washer hose from the protective plate.

6 Remove the fresh air filter.

Workshop manual DRF 400–450

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38

9 Frame, body, cab and accessories – 9.4.3 Cab fan

7 Remove the bolts which secure the plate and cab fan.

8 Detach the connector from the cab fan. 9 Remove the cab fan. 10 Replace the cab fan. 11 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.

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Workshop manual DRF 400–450

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 engine’s coolant is transmitted to the cab via the heat exchanger. The heat exchanger is located behind the fan in the external unit for fresh air intake into the cab.

1, 2

003210

3

Fresh air intake, cab 1. Heat exchanger heat 2. Heat exchanger cooling 3. Refrigerant expansion valve and temperature sensor

Workshop manual DRF 400–450

VDRF03.02GB

40

page –

9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat

Heat exchanger, cooling/heating, replacement

WARN IN G Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety.

1 Machine in service position, 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. 4 Remove the wiper arms. 5 Remove the nuts which hold the wiper motor in the protective plate. 6 Remove the protective plate.

7 Detach the washer hose from the protective plate.

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat

41

8 Remove the fresh air filter.

9

Remove the plate frame.

10 Remove the cab fan.

11 Remove the heat exchanger cover plate.

Workshop manual DRF 400–450

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. 15 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm. 16 Check for leaks and refill the AC-system with refrigerant R134a, with the intended equipment. For volume, see section F Technical data.

I M P OR TA NT Working on the air conditioning requires special authorisation.

9.4.5

Water valve

Water valve, description

page –

The water valve controls the climate control system’s capacity for heating from 0 (closed valve) to 100% (open valve). The water valve is electrically controlled.

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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4.6 Engine temperature sensor

43

Water valve, replacement

page –

1 Machine in service position, see section B Safety. 2 Detach the connector from the water valve. 3 Stop the flow of fluid to and from the water valve using hose pinch-off pliers. 4 Detach the coolant hoses from the water valve. 5 Remove the water valve from the cab floor. 6 Replace the water valve. 7 Fit in the reverse order. 8 Check coolant level.

1. Water valve 2. Steering valve

9.4.6

Engine temperature sensor

Sensor, engine temperature, description

page –

The coolant temperature sensor sits on the engine and detects engine coolant temperature. See supplier documentation, engine. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE, menu 2. For location, see section 1 Engine.

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 machine’s engine. Activation and deactivation of the compressor is handled by an electromagnetic clutch, which is controlled by a thermostat.

001242

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.6 CLIMATE, menu 6.

Workshop manual DRF 400–450

VDRF03.02GB

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page –

9 Frame, body, cab and accessories – 9.4.7 Compressor

Compressor, replacement (engine alternative Volvo)

WARN IN G Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety.

1 Machine in service position, 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 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. 7 Fit in the reverse order. 8 Check for leaks and refill the AC-system with refrigerant R134a, with the intended equipment. For volume, see section F Technical data.

I M P OR TA NT Working on the air conditioning requires special authorisation.

VDRF03.02GB

Workshop manual DRF 400–450

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.

1

The compressor is driven by V-belts directly by the machine’s engine. Activation and deactivation of the compressor is handled by an electromagnetic clutch, which is controlled by a thermostat.

005000

2

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.6 CLIMATE, menu 6.

1. Compressor air conditioning 2. Turnbuckle

Compressor, replacement (engine alternative Cummins QSM11)

page –

WARN IN G Personal injury, environmental damage.

1

Read the safety instructions for refrigerant, see section B Safety.

2 005000

1 Machine in service position, see section B Safety.

1. Compressor air conditioning 2. Turnbuckle

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 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. 7 Fit in the reverse order.

Workshop manual DRF 400–450

VDRF03.02GB

46

9 Frame, body, cab and accessories – 9.4.8 Condenser

8 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 Working on the air conditioning requires special authorisation.

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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4.8 Condenser

page –

47

Condenser, replacement

WARN IN G Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety.

1 Machine in service position, see section B Safety. 1. Radiator 2. Condenser

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 inlet and outlet hoses from the condenser. 4 Remove the bolts which secure the condenser at the top edge and lift the condenser out in a suitable way. 5 Replace the condenser, fitting it in the reverse order. 6 Check for leaks and refill the AC-system with refrigerant R134a, with the intended equipment. For volume, see section F Technical data.

I M P OR TA NT Working on the air conditioning requires special authorisation.

Workshop manual DRF 400–450

VDRF03.02GB

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9 Frame, body, cab and accessories – 9.4.9 Moisture filter

9.4.9

Moisture filter

Moisture filter, description

page –

1

The moisture filter collects the liquid refrigerant, binds moisture and filters impurities. The reservoir functions as an expansion tank in the cooling circuit.

2

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 –

1

The pressure switch cuts off the current to the compressor’s electromagnetic clutch if the pressure in the cooling circuit becomes abnormally high or low.

2

002227

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.3 CLIMATE, menu 3.

1. Fluid reservoir, moisture filter 2. Pressure switch

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.4.11 Expansion valve

49

Pressure switch, replacement

page –

WARN IN G 1

2

Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety. 1 Machine in service position, see section B Safety. 2 Drain the machine of refrigerant, R134a.

I M P OR TA NT

002227

Working on the air conditioning requires special authorisation.

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. 6 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 Working on the air conditioning requires special authorisation.

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.

Workshop manual DRF 400–450

VDRF03.02GB

50

page –

9 Frame, body, cab and accessories – 9.4.11 Expansion valve

Expansion valve, replacement

WARN IN G Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety.

1 Machine in service position, see section B Safety. 2 Drain the AC system of refrigerant.

I M P OR TA NT Working on the air conditioning requires special authorisation.

3 Detach the AC system hoses. 4 Detach the coolant hoses. 5 Remove the heat exchanger for cooling/heating to access the expansion valve, see Heat exchanger, cooling/heating, replacement page 40. 6 Replace the expansion valve. 7 Fit in the reverse order. 8 Check for leaks and refill the AC-system with refrigerant R134a, with the intended equipment. For volume, see section F Technical data.

I M P OR TA NT Working on the air conditioning requires special authorisation.

VDRF03.02GB

Workshop manual DRF 400–450

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. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE, menu 2.

1

2

002226

3

1. Sensor cab temperature 2. Sensor temperature refrigerant 3. Sensor temperature outlet fan page –

Sensor, refrigerant temperature, replacement

WARN IN G Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety.

NOTE Requires special authorisation. 1 Machine in service position, see section B Safety. 2 Drain the AC system of refrigerant.

I M P OR TA NT Working on the air conditioning requires special authorisation.

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. 7 Fit in the reverse order.

Workshop manual DRF 400–450

VDRF03.02GB

52

9 Frame, body, cab and accessories – 9.4.13 Heat exchanger cooling

8 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 Working on the air conditioning requires special authorisation.

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

3

Fresh air intake, cab 1. Heat exchanger heat 2. Heat exchanger cooling 3. Refrigerant expansion valve and temperature sensor

VDRF03.02GB

Workshop manual DRF 400–450

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

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLIMATE, menu 5 and 8.4.4.8 CLIMATE, menu 8.

page –

Air distributor, replacement 1 Machine in service position, see section B Safety. 2 Remove the dashboard panel. 3 Remove the steering wheel shaft cover. 4 Detach the steering wheel shaft and angle it back against the operator’s seat. 5 Remove the lower cover in front of the pedal bracket. 6 Detach the air hoses from the air distributor and detach the 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

Workshop manual DRF 400–450

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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 cab’s interior: at the front of the doors and the defroster for the windscreen. There are also two adjustable air vents (flow and direction) in the instrument panel’s outside corners.

001839

There is an air inlet towards the cab’s lower part (floor).

page –

Defroster nozzles, replacement 1 Machine in service position, see section B Safety. 2 Remove the air damper manually. 3 Remove the bolts which hold the other part of the defroster nozzle in the dashboard.

VDRF03.02GB

Workshop manual DRF 400–450

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:

1

Sensor cab temperature

2.

Sensor temperature refrigerant

3.

Sensor temperature outlet fan

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE, menu 2.

2

002226

3

page –

1.

Outlet fan temperature sensor, replacement 1 Machine in service position, see section B Safety. 2 Remove the dashboard panel. 3 Remove the lower protective cover in front of the steering wheel shaft. 4 Detach the steering wheel shaft and angle it back against the operator’s seat.

1. Instrument panel 2. Steering column adjustment 3. Lower protective cover

Workshop manual DRF 400–450

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9 Frame, body, cab and accessories – 9.4.17 Sensor cab temperature

5 Detach the temperature sensor from the air distributor. 6 Fit in the reverse order.

Air distributor including temperature sensor.

9.4.17

Sensor cab temperature

Sensor, cab temperature, description

page –

The cab temperature sensor (position 1) detects the temperature of the air in the cab. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.1 CLIMATE, menu 1.

1

2

002226

3

1. Sensor cab temperature 2. Sensor temperature refrigerant 3. Sensor temperature outlet fan page –

Cab temperature sensor, replacement 1 Machine in service position, see section B Safety. 2 Remove the dashboard panel.

VDRF03.02GB

Workshop manual DRF 400–450

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. 6 Replace the temperature sensor. 7 Fit in the reverse order.

9.4.18 page –

Sensor outdoor temperature

Sensor, ambient temperature, description The ambient temperature sensor detects the temperature of the air outside the cab. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE, menu 2.

Sensor outdoor temperature page –

Ambient temperature sensor, replacement 1 Machine in service position, see section B Safety. 2 Detach the connector from the temperature sensor. 3 Remove the temperature sensor from its mounting in the cab. 4 Replace the temperature sensor. 5 Fit in the reverse order.

Workshop manual DRF 400–450

VDRF03.02GB

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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

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.3.1 CAB, menu 1.

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.5.5 Wiper motor, front

59

Washer motor and container, replacement

page –

1 Machine in service position, see section B Safety. 2 Remove the protection over the washer fluid reservoir. 3 Drain the washer fluid from the container. 4 Remove the washer motors from the fluid reservoir. 5 Remove the bolts which secure the fluid container in the cab wall.

A

003619

6 Change the washer fluid reservoir. Change the washer motor, if needed.

B

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. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.3.2 CAB, menu 2.

page –

Front wiper motor, replacement 1 Machine in service position, see section B Safety. 2 Remove the wiper arms. 3 Remove the nuts which hold the motor in the protective plate. 4 Remove the protective plate. 5 Detach the washer hose from the protective plate.

Workshop manual DRF 400–450

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 window’s wiper. The wiper arm is mounted on the motor. The motor produces the movement of the wiper. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.3.4 CAB, menu 4.

page –

Wiper motor (roof), replacement 1 Machine in service position, see section B Safety. 2 Remove the plastic cover.

3 Detach the washer hose and the connector to the wiper motor.

VDRF03.02GB

Workshop manual DRF 400–450

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. 6 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.

9.5.7 page –

Wiper motor, rear

Wiper motor, rear, description The wiper motor drives the rear window wiper. The wiper arm is mounted on the motor. The motor produces the movement of the wiper. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.3.3 CAB, menu 3.

page –

Rear wiper motor, replacement 1 Machine in service position, see section B Safety. 2 Remove the panels behind the operator’s seat. 3 Remove the screws holding the motor’s plastic cover.

4 Detach the connector from the motor. 5 Raise the plastic cover and remove the nut securing the wiper arm. Disconnect the washer hose.

Workshop manual DRF 400–450

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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

Workshop manual DRF 400–450

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 minute’s 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 section F Technical data.

1

2

3

4

5

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

1

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

D1: Diagnostic menu, see section 8 Control system group 8.4.2.1 LIGHTS, menu 1

2

The switch for attachment work lights (S105-2) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D2: Diagnostic menu, see section 8 Control system group 8.4.2.2 LIGHTS, menu 2

3

The switch for boom working lights (S105-3) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D3: Diagnostic menu, see section 8 Control system group 8.4.2.3 LIGHTS, menu 3

4

The headlights switch (S100) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D4: Diagnostic menu, see section 8 Control system group 8.4.2.4 LIGHTS, menu 4

5

The revolving beacon switch (S110) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D5: Diagnostic menu, see section 8 Control system , group 8.4.2.9 LIGHTS, menu 9

Workshop manual DRF 400–450

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6

9 Frame, body, cab and accessories – 9.6 Lighting system

Interior lighting cab, description page 72

The door NC switch (S226-LE & S226-RI) sends a voltage signal to the cab control unit (D790-1).

Door open: U = 24 V

7

The cab control unit (D790-1) transmits a "switch on lights" message 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

8

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

D6: Diagnostic menu, see section 8 Control system group 8.4.2.12 LIGHTS, menu 12

D8: Diagnostic menu, see section 8 Control system group 8.4.2.6 LIGHTS, menu 6 9

D9: Diagnostic menu, see section 8 Control system group 8.4.2.7 LIGHTS, 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 control unit (D790-2).

Checked by control system, error shown with error code.

D10: Diagnostic menu, see section 8 Control system group 8.4.2.12 LIGHTS, menu 12

11

The KIT control unit (D790-2) transmits a "switch on lights" message on the CAN bus.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.11 Control unit KIT

12

The cab control unit (D790-1) supplies voltage to the lights in and around the cab.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.1 Cab control unit

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

D13: Diagnostic menu, see section 8 Control system group 8.4.2.1 LIGHTS, 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

Workshop manual DRF 400–450

Working lights, boom, lights page 71

9 Frame, body, cab and accessories – 9.6 Lighting system

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 D16: Diagnostic menu, see section 8 Control system group 8.4.2.9 LIGHTS, menu 9

Interior lighting cab, description page 72 D17: Diagnostic menu, see section 8 Control system group 8.4.2.12 LIGHTS, menu 12 Section 4 Brakes, group 4.3.8 NO (normally open) switch, brake lights D18: Diagnostic menu, see section 8 Control system group 8.4.2.10 LIGHTS, menu 10

19

Control unit frame front (D797-F) supplies power to the front lights on the machine.

Checked by control system, error shown with error code.

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

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.

Checked by control system, error shown with error code.

21

22

23

D20: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8

Running lights, description page 68 D21: Diagnostic menu, see section 8 Control system group 8.4.2.5 LIGHTS, menu 5

Headlights, description page 68 D22: Diagnostic menu, see section 8 Control system group 8.4.2.6 LIGHTS, menu 6

Headlights, description page 68 D23: Diagnostic menu, see section 8 Control system group 8.4.2.6 LIGHTS, menu 6

Workshop manual DRF 400–450

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear

VDRF03.02GB

66

27

9 Frame, body, cab and accessories – 9.6 Lighting system

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 attachment’s lights.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.5 Control unit, attachment

34

Working lights attachment (E406-L & E406R) are switched on when the attachment’s 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 attachment’s working lights are activated.

Light on: U = 24 V

28

29

30

31

32

35

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D27: Diagnostic menu, see section 8 Control system group 8.4.2.5 LIGHTS, menu 5

Brake light, description page 69 D28: Diagnostic menu, see section 8 Control system group 8.4.2.11 LIGHTS, menu 11

Driving direction indicator, description page 69 D29: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8

Running lights, description page 68 D30: Diagnostic menu, see section 8 Control system group 8.4.2.5 LIGHTS, menu 5

Reversing light, description page 69 D31: Diagnostic menu, see section 8 Control system , group 8.4.2.11 LIGHTS, menu 11

Working lights, boom, lights page 71 D32: Diagnostic menu, see section 8 Control system group 8.4.2.3 LIGHTS, menu 3

D34: Diagnostic menu, see section 8 Control system group 8.4.2.2 LIGHTS, menu 2

Workshop manual DRF 400–450

Attachment work lights, description page 72 D35: Diagnostic menu, see section 8 Control system group 8.4.2.2 LIGHTS, menu 2

9 Frame, body, cab and accessories – 9.6 Lighting system

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 It is important that the right type of bulb is used for each area. See section F Technical data.

1

2

3

4

5

6

8

7

20 1.

17

18, 19

Rotating beacon (H428)

16

15

14

13, 12, 11

10

9

006426

21, 22, 23, 24

13. Headlights, low beam (E400L & E400R) Headlights, high beam (E402L & E402R)

2.

Interior lighting

14. NO switch, brake lights (S216)

3.

Control unit KIT (D790-2)

15. Control unit, frame front (D797-F)

4.

Multi-function lever (S162)

16. Switch, see section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments

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)

18. Control unit cab (D790-1)

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)

Workshop manual DRF 400–450

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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 machine’s position. Headlights have high beam and low beam (for meeting other traffic). Switch between low and high beam with the gear and multi-function 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 machine’s position and direction of travel. The running lights are controlled by selecting with the headlight switch. The signal travels to the cab control unit (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.5 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 machine’s position, and a limited enhancement of the view for the operator in darkness. The tail lights are controlled by selecting with the headlight switch. The signal travels to the cab control unit (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.

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

Workshop manual DRF 400–450

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. The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.

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.

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). The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.

9.6.6 page –

Driving direction indicator

Driving direction indicator, description The direction indicators are located on both the front and rear of the machine to provide surrounding traffic and the environment an indication that the machine is changing direction, i.e. turning. The direction indicators are controlled by 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). The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.8 LIGHTS, menu 8.

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.

Workshop manual DRF 400–450

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). The signal can be checked from the diagnostic menu, see section 8 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 machine’s 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). The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.9 LIGHTS, menu 9.

9.6.9 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. The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.1 LIGHTS, menu 1.

VDRF03.02GB

Workshop manual DRF 400–450

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 lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.3 LIGHTS, menu 3. The lifting boom can be equipped with two extra working lights (

page –

).

Work lights, changing (product alternative Xenon lights)

See Work lights, changing (product alternative Xenon lights) page 71.

Workshop manual DRF 400–450

VDRF03.02GB

72

9 Frame, body, cab and accessories – 9.6.11 Work lights, attachment

9.6.11 page –

Work lights, attachment

Attachment work lights, description 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 lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.2 LIGHTS, menu 2. The attachment can be equipped with two extra working lights (

page –

).

Work lights, changing (product alternative Xenon 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. The lights and their signal can be checked from the diagnostic menu, section 8 Control system , group 8.4.2.12 LIGHTS, menu 12.

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.7 Signalling system

9.7

73

Signalling system

Signalling system, function description

page –

NOTE It is important that the right type of bulb is used for each area. See section F Technical data.

2

3 D2

5

D3

D1

6

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

9

10

D11 11

D13

7

D791-1

12 13

20

D795

D22

21

22

007418

1

Pos

Description

Signal description

Reference

1

The revolving beacon switch (S110) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D1: Diagnostic menu, see section 8 Control system group 8.4.2.9 LIGHTS, menu 9

2

The switch for warning lights (hazard) (S109) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D2: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8

3

The parking brake switch (S107) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D3: Diagnostic menu, see section 8 Control system group 8.4.5.4 HYD, menu 4

4

The cab control unit (D790-1) transmits activation messages 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

5

The multi-function lever (S162) sends a voltage signal to the KIT control unit (D790-2).

Signal button pressed in: US162/H = 24 V

Gear and multi-function lever, description page 12

The direction indicator lever (S161) sends a voltage signal to the KIT control unit (D790-2).

Left: US161/6 = 24 V

6

D5: Diagnostic menu, see section 8 Control system , group 8.4.3.5 CAB, menu 5

Right: US161/1 = 24 V

Workshop manual DRF 400–450

D6: Diagnostic menu, see section 8 Control system group 8.4.2.7 LIGHTS, menu 7

VDRF03.02GB

74

9 Frame, body, cab and accessories – 9.7 Signalling system

Pos

Description

Signal description

Reference

7

The KIT control unit (D790-2) transmits activation messages on the CAN bus.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.11 Control unit KIT

8

Control unit frame rear (D797-R) supplies power to the rear lights and buzzer on the machine.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear

9

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

Control unit frame front (D797-F) supplies power to the front lights on the machine.

Checked by control system, error shown with error code.

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

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

D9: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8

Reversing light, description page 69 D10: Diagnostic menu, see section 8 Control system group 8.4.2.11 LIGHTS, menu 11

D11: Diagnostic menu, see section 8 Control system group 8.4.2.11 LIGHTS, menu 11

D13: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8

Horn, description page 76 D14: Diagnostic menu, see section 8 Control system , group 8.4.3.5 CAB, menu 5

Revolving beacon, description page 76 S15: Diagnostic menu, see section 8 Control system , group 8.4.2.9 LIGHTS, menu 9

Horn, description page 76

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

Horn, description page 76

18

The operator-in-seat NO switch (S230) sends a voltage signal to the cab control unit (D790-1) when there is a load on the operator’s seat.

Operator in seat: U = 24 V

Sensor operator in seat, description page 23

VDRF03.02GB

D18: Diagnostic menu, see section 8 Control system group 8.4.3.6 CAB, menu 6

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.7 Signalling system

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 operator’s attention to the warning message.

Checked by control system, error shown with error code.

D19: Diagnostic menu, see section 8 Control system , group 8.4.3.6 CAB, menu 6

20

In the event of warnings, the KID control unit (D795) activates the warning light to draw the operator’s attention to the warning message.

A clicking sound is audible when then termination resistor is activated.

Section 11 Common electrics, group 11.5.3.12 KID control unit

21

The attachment control unit (D7911) supplies voltage to the automatic spreading buzzer during automatic spreading.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.5 Control unit, attachment

22

The automatic spreading buzzer (H9003) is activated when automatic spreading 20'-40' is activated.

Buzzer active: U = 24 V

Section 7 Load handling group 7.5.13 Buzzer, automatic spreading 20’-40’ D22: Diagnostic menu, see section 8 Control system , group 8.4.9.15 ATTACH, menu 15

Signalling system, component position

page –

1

3

2

5

4

16, 17

15

12

13, 14

11

10

9

8

7

006427

6

10.

Switch, see section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments

Buzzer cab (H853)

11.

Horn (H850)

4.

Control unit KID (D795)

12.

Make-contact operator in seat (S230)

5.

Attachment control unit (D791-1)

13.

Control unit cab (D790-1)

1.

Rotating beacon (H428)

2.

Control unit KIT (D790-2)

3.

6.

14.

Automatic spreading buzzer (H9003)

Relay loud horn (K3016)

7.

Direction indicators front (H422 & H423)

15.

Control unit, frame rear (D797-R)

8.

Control unit, frame front (D797-F)

16.

Direction indicators rear (H426 & H427)

17.

Back-up alarm (H965)

9.

Loud horn (H850-1)

Workshop manual DRF 400–450

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). The signal can be checked from the diagnostic menu, see section 8 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 –

Flashing hazard lights

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 operator’s 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. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.3.6 CAB, menu 6..

9.7.5 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. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.

VDRF03.02GB

Workshop manual DRF 400–450

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.

Workshop manual DRF 400–450

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.

C

The windows on the Spirit Delta cab are made of tinted hardened glass, except the roof window which is made of polycarbonate plastic.

D

As an option, the cab can be equipped with windows of laminated glass.

A

E

B

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

Workshop manual DRF 400–450

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 operator’s 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. 1 Machine in service position, see section B Safety. 2 Remove the key strip. 3 Remove the broken window pane and check that no glass or other particles remain in the window pane’s groove on the strip. Cut apart silicone joints with a sharp tool.

NOTE Make sure that no silicone adhesive remains between the window pane and the strip by the window pane’s lower front edge. If the roof window is to be 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 window’s strength.

4 Clean all surfaces thoroughly. Remove old remains of silicone with a razor blade or similar.

Workshop manual DRF 400–450

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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.

1

2

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.

3

Use spacers against the roof member to ensure that the distances are obtained.

006268

1

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

Workshop manual DRF 400–450

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 pane’s edges and by the protection over the frame’s 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. 1 Machine in service position, see section B Safety.

Workshop manual DRF 400–450

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82

9 Frame, body, cab and accessories – 9.9.2 Side window

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

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.9.2 Side window

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.

Workshop manual DRF 400–450

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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 window’s surface at regular intervals, and only clean with washer fluid or mild cleaning agents. Rinse with lukewarm water. Replace the roof window if it is damaged, cracked, or scratched! 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

Workshop manual DRF 400–450

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 –

A

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.

B

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

2

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.

Workshop manual DRF 400–450

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.

1

CA.SE

L

MENU

2

The monitor is mounted on a hinged bracket to the left in front of the door in the cab.

VOL

3 BRI

5

007416

4

1. Selection of camera 2. Menu 3. Brightness 4. Volume setting 5. Switching ON/OFF

VDRF03.02GB

Workshop manual DRF 400–450

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.

1

3 4

003206

2

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

Workshop manual DRF 400–450

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 operator’s door and the right is the emergency exit. The door has: •

rail

•

handle

•

key lock

•

openable window (passenger door

)

Switches in the doors’ locks sense if the door is open. The switch is used to light the interior lighting and warn of an open door. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.2.12 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 machine’s 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 The cab undercarriage is fitted on the machine’s chassis (frame) via a mounting. The mounting to the chassis consists of four ball bearing metal rollers which run in rails above the machine’s frame.

VDRF03.02GB

Workshop manual DRF 400–450

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 –

1

2

3 The cab undercarriage is fitted on the machine’s chassis (frame) via a mounting. The mounting runs in a lift mast which is secured in the machine’s 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

4

1. Hydraulic cylinder, vertically adjustable cab 2. Mast, vertically adjustable cab 3. Cab undercarriage, vertically adjustable cab 4. Safety lock

Workshop manual DRF 400–450

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.

A

D ANGER The cab may start to move. Fatal danger!

B

C

A. Position, lock handle B. Lock pin C. Lock handle for securing cab

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!

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.10.4 Sliding cab

91

Hydraulic sliding cab, function description

page –

Condition

Reference value

Reference

Doors

Closed

Doors, description page 88.

2

D1

D2

1 D790-1

3, 13 D12

4,14

D797-O 5

D4 P1

7

12

A

LS

11, 17

TP B

T1

8

10, 16 006901

6, 9, 15

Pos

Explanation

Signal description

Reference

1

Switch (S177) sliding cab sends a voltage signal to Control unit, cab (D790-1).

U = 24 V

Controls and instruments, overview page 5

Contact closed door, sends signal to control unit cab when door is closed.

U = 24 V

3

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.

Section 11 Common electrics, group 11.5.3.1 Cab control unit

4

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 = 435–650 mA

Section 11 Common electrics, group 11.5.3.4 Control unit, frame option

2

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

D4: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and 4

Workshop manual DRF 400–450

VDRF03.02GB

92

9 Frame, body, cab and accessories – 9.10.4 Sliding cab

Pos

Explanation

Signal description

Reference

5

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

6

Control valve, option frame sends control signal to shuttle valve option.

-

Control valve, option frame, description page 93

7

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

8

The main pumps pump oil from the tank.

Pressure plate "Max. pressure hydraulic oil pumps" on left frame member.

Section 10 Common hydraulics, group 10.4.2 Axial piston pump with variable displacement

9

Control valve, option frame pressurises valve block sliding cab.

-

Control valve, option frame, description page 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 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 100

13

The cab control unit (D790-1) transmits "dampen sliding cab" 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

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.

-

Section 11 Common electrics, group 11.5.3.4 Control unit, frame option

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.

-

Valve block, manual sliding cab, description page 97

17

Hydraulic motor sliding cab reduces the speed of sliding cab.

-

Hydraulic motor, sliding cab, description page 97

15

D4: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and 4

D12: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 2

D4: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and 4

Control valve, option frame, description page 93 D4: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and 4

Hydraulic diagram, sliding cab Hydraulic diagram, sliding cab + support jacks

VDRF03.02GB

Workshop manual DRF 400–450

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 with variable displacement.

9.10.4.3 page –

Control valve, option frame

Control valve, option frame, description

The hydraulic sliding cab is controlled by a separate section in control valve, option frame. The control valve is an electro-hydraulically controlled, proportional and pressure-compensated directional valve. Electrically controlled 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

Workshop manual DRF 400–450

VDRF03.02GB

94

9 Frame, body, cab and accessories – 9.10.4.3 Control valve, option frame

Valve slide, sliding cab

1 6

2

5

3

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

4

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, frame option (D797-O).

000624

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3.

1. Load signal (LS) 2. Pressure supply (P) 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). The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 4.

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.10.4.3 Control valve, option frame

95

Control valve, option frame, replacement

page –

NOTE Read the safety instructions for oil before working, see section B Safety. 1 Machine in service position, see section B Safety. 2 Depressurise the brake and hydraulic systems, see section B Safety. 3 Mark up and detach the hydraulic hoses from the control valve.

1

NOTE 6

2

5

3

Plug all connections immediately to protect the hydraulic system from impurities. 4 Mark up and detach the wiring from the control valve. 5 Remove the control valve.

4

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

000624

Check that the O-rings on the hydraulic connections are intact and in place.

1. Load signal (LS) 2. Pressure supply (P) 3. Tank return (T1) 4. Connection hydraulic motor (B) 5. Tank return (TP) 6. Connection hydraulic motor (A)

NOTE Transfer one part at a time so that the marking is not mixed up. 7 Mark up the servo valves on the new control valve. 8 Fit the valve. 9 Connect the wiring to the control valve in accordance with the marking. 10 Connect the hydraulic hoses to the control valve in accordance with the marking.

NOTE Check that the O-rings are intact and fitted correctly.

Workshop manual DRF 400–450

VDRF03.02GB

96

9 Frame, body, cab and accessories – 9.10.4.3 Control valve, option frame

11 Close the drain valve on the accumulator charging valve.

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

12 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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. 13 Start the engine and check for leaks. 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. 15 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.

VDRF03.02GB

Workshop manual DRF 400–450

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

Valve block, manual sliding cab, description

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 –

1

2

3

4

5

6

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 6. Indicator plate, damping

Workshop manual DRF 400–450

VDRF03.02GB

98

9 Frame, body, cab and accessories – 9.10.4.6 Hydraulic motor, sliding cab

Hydraulic motor, sliding cab, replacement

page –

NOTE Read the safety instructions for oil before working, see section B Safety. 1 Machine in service position, see section B Safety. 2 Depressurise the hydraulic 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.

10 Close the drain valve on the accumulator charging valve.

NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 11 Fit in the reverse order.

12 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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. 13 Check the function.

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.10.4.7 Chain, sliding cab

99

14 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.

9.10.4.7

Chain, sliding cab

Chain, sliding cab, description

page –

1

2

3

4

5

6

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) 2. Indicator plate, damping 3. Chain, sliding cab 4. Hydraulic motor, sliding cab 5. Control valve, sliding cab 6. Indicator plate, damping page –

Chain and chain wheel, sliding cab, replacement 1 Machine in service position, see section B Safety. 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. 6 Fit in the reverse order. 7 Adjust the chain with the adjusting screw. 8 Tighten the chain tensioner.

Workshop manual DRF 400–450

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, description

Sensor end position damping indicates when the cab is near the end position and is used to activate end position damping. The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 2. page –

Position sensor, checking and adjustment See section 7 Load handling.

VDRF03.02GB

Workshop manual DRF 400–450

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.

2

D1

D2

1 D790-1 4, 14, 17

D797-O D17

D4 5

D15

3, 16, 22

10

18 11, 20

7

P1

A

LS

B

15

D13

12, 21

13

TP T3

T1

6, 9, 19

013033

8

Pos

Explanation

Signal description

Reference

1

Switch vertically adjustable cab (S177) sends a voltage signal to Control unit, cab (D790-1).

U = 24 V

Controls and instruments, overview page 5

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.

Checked by control system, error shown with error code.

2

3

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 Section 11 Common electrics, group 11.5.3.1 Cab control unit

Workshop manual DRF 400–450

VDRF03.02GB

102

9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab

Pos

Explanation

Signal description

Reference

4

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 = 435–650 mA

Section 11 Common electrics, group 11.5.3.4 Control unit, frame option

Servo valve, raise cab (Y6016) or servo valve, lower cab (Y6017) pressurises the sliding cab slide in control valve, option frame.

-

6

Control valve, option frame sends a control signal to shuttle valve option.

-

Control valve, option frame, description page 104

7

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

8

The main pumps pump oil from the tank.

See pressure plate on left frame beam.

Section 10 Common hydraulics, group 10.4.2 Axial piston pump with variable displacement

9

Control valve, option frame pressurises the accumulator and the load control valve.

-

Control valve, option frame, description page 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

5

D4: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and 4

Control valve, option frame, description page 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

Control unit, frame option (D797-O) sends "cab up" on the CAN bus.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.4 Control unit, frame option

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

D13: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 2

D15: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 2

Workshop manual DRF 400–450

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.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.1 Cab control unit

17

Control unit, frame option (D797-O) reduces the control current to servo valve raise cab (Y6016) or servo lower valve cab (Y6017) in control valve, option frame.

-

Section 11 Common electrics, group 11.5.3.4 Control unit, frame option

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 vertically adjustable cab.

-

Control valve, option frame, description page 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.

Section 11 Common electrics, group 11.5.3.1 Cab control unit

18

D17: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and 4

Control valve, option frame, description page 104 D17: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 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 with variable displacement.

Workshop manual DRF 400–450

VDRF03.02GB

104

9 Frame, body, cab and accessories – 9.10.5.2 Control valve, option frame

9.10.5.2

Control valve, option frame

Control valve, option frame, description

page –

1 6

2

5

3

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, vertically adjustable cab.

4

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) 2. Pressure supply (P) 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). The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3.

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 –

Control valve, option frame, replacement

See Control valve, option frame, replacement page 95.

9.10.5.3 page –

Shuttle valve, frame option

Shuttle valve, frame option, description

See section 10 Common hydraulics , group 10.5.3 Shuttle valve.

VDRF03.02GB

Workshop manual DRF 400–450

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.

Workshop manual DRF 400–450

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 –

1

2

3 The hydraulic cylinder lifts the inner mast and thus the cab.

001873

4

1. Hydraulic cylinder, vertically adjustable cab 2. Mast, vertically adjustable cab 3. Cab undercarriage, vertically adjustable cab 4. Safety lock

Hydraulic cylinder, vertically adjustable cab, replacement

page –

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

2 Machine in service position, see section B Safety. 3 Depressurise the brake and hydraulic systems, see section B Safety. 4 Mark up and detach the hydraulic hoses from the extension cylinder.

NOTE Plug all hydraulic connections immediately.

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder, vertically adjustable cab

107

5 Release the upper cylinder mounting (position 1) from the moving part of the cab frame.

1 2

008206

3

1. Upper mounting hydraulic cylinder 2. Retaining bracket hydraulic cylinder 3. Hydraulic cylinder, vertically adjustable cab 6 Remove the load control valve and compress the hydraulic cylinder.

NOTE Plug all hydraulic connections immediately. 7 Attach hoisting equipment to the hydraulic cylinder. 8 Remove the hydraulic cylinder’s 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

12 Start the engine and check for leaks.

Load control valve

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9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder, vertically adjustable cab

13 Close the drain valve on the accumulator charging valve.

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

14 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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. 15 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. page –

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

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Workshop manual DRF 400–450

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 –

1

2

3 The mast holds the cab secure and enables raising and lowering.

001873

4

1. Hydraulic cylinder, vertically adjustable cab 2. Mast, vertically adjustable cab 3. Cab undercarriage, vertically adjustable cab 4. Safety lock

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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 –

1

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.

000618

2

The sensor indicates when the cab is completely lowered. When the cab is raised, the machine’s speed is reduced and the transmission is blocked in second gear.

1. Sensor, end position damping 2. Sensor, end position lowered cab page –

Position sensor, checking and adjustment See section 7 Load handling.

VDRF03.02GB

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.10.5.9 Sensor, end position damping

9.10.5.9

111

Sensor, end position damping

Sensor, end position damping, description

page –

1

The signal can be checked from the diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.

000618

2

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 machine’s speed is reduced and the transmission is blocked in second gear.

1. Sensor, end position damping 2. Sensor, end position lowered cab page –

Position sensor, checking and adjustment See section 7 Load handling.

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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 cylinder’s piston side and tank, and makes it possible to lower the cab if the machine becomes depressurised or deenergised.

001978

A

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

A. Lock lug

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Workshop manual DRF 400–450

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 driver’s 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 1 Machine in service position, see section B Safety. 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.

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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. 8 Fit in the reverse order.

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

Workshop manual DRF 400–450

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.

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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).

5

4 6

8

2 1

VDRF03.02GB

001511

3

7

1.

Frame’s front part with drive axle mounting

2.

Cab mounting (4 points)

3.

Steering axle mounting

4.

Frame’s rear part with counterweights

5.

Boom mounting

6.

Engine compartment with mountings for engine and transmission

7.

Beam pair

8.

Mounting for front wing

Workshop manual DRF 400–450

9 Frame, body, cab and accessories – 9.13 Body

9.13

117

Body

Body, description

page –

The body’s components comprise:

3 1

002213

2

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 machine’s work environment requires such (

9.13.2 page –

).

Hood engine compartment

Hood engine compartment, description The machine’s 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.

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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 machine’s 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 machine’s lifting capacity.

•

Upper horizontal counterweight. Under the horizontal counterweight, there are smaller counterweights whose dimensions and quantity are adapted to balance the machine’s lifting capacity.

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.

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Workshop manual DRF 400–450

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.

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9 Frame, body, cab and accessories – 9.14 Central lubrication

Central lubrication, adjusting lubrication times

page –

The central lubrication’s pause and run-time must be set after replacement, the setting is unique to each machine, depending on the machine’s 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

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

Pause-time [hours]

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Run-time Run-time is how long the pump is activated every time. Run-time can be adjusted between 2 and 30 minutes. Pause-time is adjusted with the blue handle (position 2). Switch position

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

Run-time [minutes]

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

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Workshop manual DRF 400–450

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 motor’s 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

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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 system’s first distribution block (i.e. the block closest to the pump) has an indicator pin. If the pin moves forward and backward (in time with the piston movements), this indicates that grease is pumped 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

Workshop manual DRF 400–450

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.

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9 Frame, body, cab and accessories – 9.15 Paint/coatings

Workshop manual DRF 400–450

10 Common hydraulics

1

10 Common hydraulics

Table of Contents 10 Common hydraulics mm mm mm mm mm mm

10 Common hydraulics....................................................................................... 3 10.2 Safety valves .............................................................................................. 3 10.2.1 Accumulator drain valve ........................................................................ 3 10.2.2 Attachment relief valve .......................................................................... 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

Workshop manual DRF 400–450

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10 Common hydraulics

Workshop manual DRF 400–450

10 Common hydraulics

3

10 Common hydraulics

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.

Workshop manual DRF 400–450

VDRF03.02GB

4

10 Common hydraulics – 10.2.2 Attachment relief valve

10.2.2

Attachment relief valve

Attachment relief valve, description

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

Workshop manual DRF 400–450

10 Common hydraulics – 10.3 Tanks and accumulators

10.3 10.3.1

5

Tanks and accumulators Tank

Tank, description

page –

1

2

1

3

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.

4

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.

5

The oil level is checked on the level glass on the tank’s side when all hydraulic cylinders are in the bottom position.

001457

5

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

Pipes and hoses, general See Pipes and hoses, general page 31.

Workshop manual DRF 400–450

VDRF03.02GB

6

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 pump’s input shaft and the other rotates freely. The gear pump’s 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 transmission’s power take-off. Pump speed is directly dependent on engine speed. Pump flow increases and engine speed increases.

2

000006

1

The illustration shows hydraulic oil pump alternative Rexroth 1. Brake fluid pump 2. Pump cooling and filtration page –

Gear pump, replacement (hydraulic oil pump alternative Rexroth)

NOTE Read the safety instructions for oil before working, see section B Safety. 1 Machine in service position, see section B Safety. 2 Depressurise the brake and hydraulic systems, see section B Safety. 3 Mark up and release the hydraulic hoses from the gear pump.

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.1 Gear pump with fixed displacement

7

4 Remove the gear pump. Remove the attaching bolts, pull the pump out backwards and lift it away. 5 Transfer the connection adapters to the new gear pump.

6 Remove the spacer ring from the gear pump or axial piston pump. Clean the O rings’ contact surfaces on the spacer ring. 7 Check the O-rings and replace as needed. Install the O-rings on the spacer ring. Brush sealing silicone on the sealing face against 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.

Workshop manual DRF 400–450

VDRF03.02GB

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10 Common hydraulics – 10.4.1 Gear pump with fixed displacement

9 Brush sealing silicone on the gear pump’s sealing face against the spacer ring; see section F Technical data. 10 Fit the gear pump 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 pump’s retaining bolts.

11 Connect the hydraulic hoses to the gear pump.

NOTE Check that the O-rings are intact and are fitted correctly.

12 Close the drain valve on the accumulator charging valve.

13 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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.

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.1 Gear pump with fixed displacement

9

14 Turn on the main electric power and start the engine. 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 Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

NOTE If the pump is replaced due to malfunction, change the oil 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 Read the safety instructions for oil before working, see section B Safety. 1 Machine in service position, see section B Safety. 2 Depressurise the brake and hydraulic systems, see Workshop Manual section 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.

Workshop manual DRF 400–450

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10 Common hydraulics – 10.4.1 Gear pump with fixed displacement

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 Brush sealing silicone on the brake pump’s sealing surface, see Workshop Manual section F Technical data. 7 Fit the brake pump on the main pump. Position the pump and check that the pump’s splines engage in the shaft in the main pump. Fit the pump’s attaching bolts.

8 Connect the hydraulic hoses to the brake pump.

NOTE Check that the O-rings are intact and are fitted correctly.

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.1 Gear pump with fixed displacement

11

9 Close the drain valve and tighten the lock ring on the accumulator charging valve.

10 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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. 11 Turn on the main electric power and start the engine. 12 Check that the hose connections and seal between gear pump and axial piston pump are airtight. 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 Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

NOTE If the pump is replaced due to malfunction, change the oil and filters as well.

Workshop manual DRF 400–450

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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 –

1

2

3

4

5

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.

6

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

7

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

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10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

13

Axial piston pump with variable displacement, description (hydraulic oil pump alternative SauerDanfoss)

page –

7

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 attachment’s control valve. At boom in pump 2 is disconnected.

3

4

3

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.

4

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.

2

On the right pump’s 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.

1

011055

On the left pump’s 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

Workshop manual DRF 400–450

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10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump with variable displacement, 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

8

6

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

P

Pos

Explanation

Signal description

Reference

1

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

2

Control signal goes to the shuttle valve that sends the load signal on to hydraulic oil pumps No. 3 and No 4.

See pressure plate Servo pressure lift and extension on left frame member.

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

3

Hydraulic oil pumps No. 3 and No. 4 increase the flow.

See pressure plate Max. pressure hydraulic oil pumps on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12

4

Solenoid valve, unloading main pump (Y6062) leads load signal on to hydraulic oil pump No. 1 and the shuttle valve (position 5).

See pressure plate Servo pressure lift and extension on left frame member.

Section 7 Load handling, group 7.3.9 Valve block pump unloading

5

The shuttle valve sends load signal on to hydraulic oil pump No. 2.

See pressure plate Servo pressure lift and extension on left frame member.

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

15

Pos

Explanation

Signal description

Reference

6

Hydraulic oil pumps No. 1 and No. 2 increase the flow.

See pressure plate Max. pressure hydraulic oil pumps on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12

7

If any attachment function is activated the Control unit frame rear (D797-R) activates Solenoid valve top hydraulics (Y6003).

U = 24 V

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear

8

Solenoid valve top hydraulics (Y6003) controls an unloaded constant pressure to hydraulic oil pump No. 2, this functions as a load signal.

-

Section 7 Load handling, group 7.4.2 Valve block top lift hydraulics

9

The shuttle valve sends load signal on to hydraulic oil pump No. 2.

-

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

10

Hydraulic oil pump No. 2 increases the flow.

See pressure plate Max. pressure hydraulic oil pumps on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12

11

When Solenoid valve top hydraulics (Y6003) is not activated, the unloaded pressure is directed to tank.

-

Section 7 Load handling, group 7.4.2 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

The shuttle valve sends load signal on to hydraulic oil pumps No. 3 and 4.

-

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

14

Hydraulic oil pumps No. 3 and No. 4 increase the flow.

See pressure plate Steering pressure, on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12

15

The priority valve controls the pressure from the pumps to the steering valve.

See pressure plate Steering pressure, on left 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

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear

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

Workshop manual DRF 400–450

Section 7 Load handling, group 7.3.9 Valve block pump unloading

VDRF03.02GB

16

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump with variable displacement, function description (hydraulic oil pump alternative Sauer-Danfoss)

page –

D790-1

1

12

D797-R P

7, 16 D7

P LS

D7

LS

P1

P

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

1

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

2

Control signal goes to the shuttle valve that sends the load signal on to hydraulic oil pump No. 2.

See pressure plate Servo pressure lift and extension on left frame member.

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

3

Hydraulic oil pump No. 2 increases the flow.

See pressure plate Max. pressure hydraulic oil pumps on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Sauer-Danfoss) page 13

4

Solenoid valve, unloading main pump (Y6062) leads load signal on to hydraulic oil pump No. 1 and the shuttle valve (position 5).

See pressure plate Servo pressure lift and extension on left frame member.

Section 7 Load handling, group 7.3.9 Valve block pump unloading

5

The shuttle valve sends load signal on to hydraulic oil pump No. 1.

See pressure plate Servo pressure lift and extension on left frame member.

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

17

Pos

Explanation

Signal description

Reference

6

Hydraulic oil pump No. 1 increases the flow.

See pressure plate Max. pressure hydraulic oil pumps on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12

7

If any attachment function is activated the Control unit frame rear (D797-R) activates Solenoid valve top hydraulics (Y6003).

U = 24 V

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear

8

Solenoid valve top hydraulics (Y6003) controls an unloaded constant pressure to hydraulic oil pump No. 1, this functions as a load signal.

-

Section 7 Load handling, group 7.4.2 Valve block top lift hydraulics

9

The shuttle valve sends load signal on to hydraulic oil pump No. 1.

-

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

10

Hydraulic oil pump No. 1 increases the flow.

See pressure plate Max. pressure hydraulic oil pumps on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12

11

When Solenoid valve top hydraulics (Y6003) is not activated, the unloaded pressure is directed to tank.

-

Section 7 Load handling, group 7.4.2 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

The shuttle valve sends load signal on to hydraulic oil pump No. 2.

-

Shuttle valve, description (hydraulic oil pump alternative Rexroth) page 32

14

Hydraulic oil pump No. 2 increases the flow.

See pressure plate Steering pressure, on left frame member.

Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12

15

The priority valve controls the pressure from the pumps to the steering valve.

See pressure plate Steering pressure, on left 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

Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear

17

Solenoid valve pump unloading (Y6062) leads the pressure from the control valve to Solenoid valve (Y6003).

-

Section 7 Load handling, group 7.3.9 Valve block pump unloading

18

When Solenoid valve top hydraulics (Y6003) is not activated, the unloaded pressure is directed to tank.

-

Section 7 Load handling, group 7.3.9 Valve block pump unloading

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

Workshop manual DRF 400–450

VDRF03.02GB

18

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Hydraulic oil pump, checking (hydraulic oil pump alternative Rexroth)

page –

NOTE Read the safety instructions for oil before working, see section B Safety. 1 Operate and warm up the machine so that the hydraulic oil reaches operating temperature, approx. 50 °C. 2 Stop the engine 3 Connect a pressure gauge to measuring outlet on hydraulic oil pump 1. 4 Start the engine and run it at idling speed. 5 Check the standby pressure for one pump at a time in the following order: Hydraulic oil pump 1: 1.8 MPa Hydraulic oil pump 2: 2.1 MPa Hydraulic oil pump 3: 2.9 MPa Hydraulic oil pump 4: 3.1 MPa 1. Hydraulic oil pump 1 2. Hydraulic oil pump 2 3. Hydraulic oil pump 3 4. Hydraulic oil pump 4

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 3–8 on all four pumps.

MPa

MPa

MPa

MPa MPa

MPa

MPa

920643.0024

VDRF03.02GB

001028

MPa

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

19

Axial piston pump, checking (hydraulic oil pump alternative Sauer-Danfoss)

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. 4 Start the engine and run it at idling speed. 5 Check the standby pressure for one pump at a time in the following order: Hydraulic oil pump 1: 2.9 MPa Hydraulic oil pump 2: 3.0 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.

1. Hydraulic oil pump 1 2. Hydraulic oil pump 2

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 3–8.

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa

MPa A49195.0400

Workshop manual DRF 400–450

VDRF03.02GB

20

page –

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump with variable displacement, replacement (hydraulic oil pump alternative Rexroth)

NOTE Read the safety instructions for oil before working, see section B 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 pump’s 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. 3 Depressurise the brake and hydraulic systems, see section 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 Plug all unions at once to protect the hydraulic system from contamination.

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

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 Check that the O-rings are intact and fitted correctly. 12 Apply sealing silicone on the axial piston pump flange where it mates with the gearbox, see section F Technical data. 13 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.

Workshop manual DRF 400–450

VDRF03.02GB

22

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

16 Connect the hydraulic hoses to the axial piston pump in accordance with the marking.

NOTE Check that the O-rings are intact and fitted correctly.

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 spacer ring. Brush sealing silicone on the sealing face against 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

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

23

20 Brush sealing silicone on the gear pump’s sealing face against the spacer ring; see section F Technical data.

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 pump’s shaft engages the axial piston pump’s 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. 23 Close the drain valve on the accumulator charging valve.

Workshop manual DRF 400–450

VDRF03.02GB

24

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

24 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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. 25 Turn on the main electric power and start the engine. 26 Check that the hose connections and seal between gear pump and axial piston pump are airtight. 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 If the pump is replaced due to malfunction, change the oil and filter in the hydraulic system as well.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

page –

25

Axial piston pump with variable displacement, replacement (hydraulic oil pump alternative SauerDanfoss)

NOTE Read the safety instructions for oil before working, see section B 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 pump’s 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. 3 Depressurise the brake and hydraulic systems, see section 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.

Axial piston pump 2 (left) Axial piston pump 1 (right)

7 Mark up and detach the hydraulic hoses from the axial piston pump.

Workshop manual DRF 400–450

VDRF03.02GB

26

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

NOTE Plug all unions at once to protect the hydraulic system from 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 Check that the O-rings are intact and fitted correctly. 12 Apply sealing silicone on the axial piston pump flange where it mates with the gearbox, see section F Technical data. 13 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.

Axial piston pump 2 (left) Axial piston pump 1 (right)

VDRF03.02GB

15 Fill the pump with oil through the connections on the top.

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

27

Axial piston pump 2 (Left) Axial piston pump 1 (right)

16 Connect the hydraulic hoses to the axial piston pump in accordance with the marking.

NOTE Check that the O-rings are intact and fitted correctly. 17 Brush sealing silicone on the gear pump’s sealing surface; see section F Technical data.

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 pump’s shaft engages the axial piston pump’s 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.

Workshop manual DRF 400–450

VDRF03.02GB

28

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

20 Close the drain valve on the accumulator charging valve and tighten the lock ring.

21 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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. 22 Turn on the main electric power and start the engine. 23 Check that the hose connections and seal between gear pump and axial piston pump are airtight. 24 Check the pump pressures, see Axial piston pump, checking (hydraulic oil pump alternative Sauer-Danfoss) page 19. 25 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 If the pump is replaced due to malfunction, change the oil and filter in the hydraulic system as well.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

page –

29

Axial piston pump with variable displacement, bleeding (hydraulic oil pump alternative Rexroth)

NOTE Read the safety instructions for oil before working, see section B Safety. 1 Remove the hydraulic oil tank’s breather filter. 2 Connect compressed air at max. pressure max. 10 kPa to the hydraulic oil tank’s connection for breather filter.

3 Loosen the hoses to the hydraulic system’s feed from the axial piston pump one at a time and let oil flow out. Tighten the connections when oil free of air flows out. 4 Remove the compressed air from the tank and fit the breather filter. 5 Turn on the main electric power and start the engine. 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 –

Axial piston pump with variable displacement, bleeding (hydraulic oil pump alternative SauerDanfoss)

NOTE Read the safety instructions for oil before working, see section B Safety. 1 Remove the hydraulic oil tank’s breather filter. 2 Connect compressed air at max. pressure max. 10 kPa to the hydraulic oil tank’s connection for breather filter.

Workshop manual DRF 400–450

VDRF03.02GB

30

10 Common hydraulics – 10.4.3 Pipes and hoses

Axial piston pump 2 (left) Axial piston pump 1 (right)

3 Loosen the hoses to the hydraulic system’s 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. 5 Turn on the main electric power and start the engine. 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

Pipes and hoses, general See Pipes and hoses, general page 31.

VDRF03.02GB

Workshop manual DRF 400–450

10 Common hydraulics – 10.5 Hoses, pipes and valves

10.5

31

Hoses, pipes and valves

10.5.1

Pipes and hoses

Pipes and hoses, general

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, see section F Technical data.

NOTE Straight coupling requires a counterhold wrench to prevent damage to the O-ring. 7.

The O-rings must not be oiled when fitted.

Hose length

C/L

Hose length is measured on a laid-out hose between the sealing 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.

Workshop manual DRF 400–450

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

Shuttle valve, description (hydraulic oil pump alternative Rexroth)

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.

1

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.

Chooses between the pressure signal from the control valve for 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

4

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

Workshop manual DRF 400–450

10 Common hydraulics – 10.5.3 Shuttle valve

33

Shuttle valve, description (hydraulic oil pump alternative Sauer-Danfoss)

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.

1

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.

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 main pump 1. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Sauer-Danfoss) page 13.

2.

Chooses between the pressure signal from the control valve for 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

4

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 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 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.

Workshop manual DRF 400–450

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10 Common hydraulics – 10.5.4 Collection block, filtered returns

10.5.4

Collection block, filtered returns

Collection block, filtered returns, description

page –

1

The block collects several return lines from different components and leads these on back to the tank through the tank filters.

2

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 –

1

The block collects several return lines from different valves and leads these directly back to the tank.

2

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

Workshop manual DRF 400–450

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, function description

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.

˚C

9

˚C

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

4

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.

M

5 2 8 7

6

007414

1

˚C 3 Pos

Description

Signal value

Reference

1

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

-

Gear pump with fixed displacement, description page 6

2

The hydraulic oil cooler cools the oil.

-

Hydraulic oil cooler, description page 37

3

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

5

The cooling fan (M668) increases air flow through the radiator.

-

Cooling fan, description page 38

6

The hydraulic oil filters clean the hydraulic oil.

-

Hydraulic oil filter, description page 43

7

Some of the oil is pumped through the hydraulic oil fine-filter for deep cleaning.

-

Fine filter hydraulic oil, description page 47

8

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

4

D3: Diagnostic menu, see section 8 Control system , group 8.4.5.1 HYD, menu 1 Section 11 Common electrics, group 11.5.3.3 Control unit, frame rear D4: Diagnostic menu, see section 8 Control system , group 8.4.5.1 HYD, menu 1

Workshop manual DRF 400–450

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10 Common hydraulics – 10.6.1 Tank heater

Pos

Description

Signal value

Reference

9

The KID control unit (D795) shows hydraulic oil temperature in the display.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.12 KID control unit

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.

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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.

Workshop manual DRF 400–450

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 Read the safety instructions for oil before working, see section B Safety. 1 Machine in service position, see section B Safety. 2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, changing page 47.

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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 Plug all unions at once to protect the hydraulic system from contamination. 4 Disconnect the cabling from the cooling fan. 5 Remove the attaching bolts and lift away the cooler. 6 Transfer the cooling fan to the new cooler. 7 Install the cooler. 8 Connect the cabling to the cooling fan. 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. 10 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.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

10.6.3

Cooling fan

Cooling fan, description

page –

The electric cooling fan is forcing. The cooling fan is located at the rear of the cooler. The fan draws air from the machine’s outside through the cooler. Openings in the side cover allows air to pass through the cooler. The 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

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Workshop manual DRF 400–450

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 tank’s 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). The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1.

Hydraulic oil temperature sensor, change

page –

NOTE Read the safety instructions for oil before working, see section B Safety. 1 Machine in service position, see section B Safety. 2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, changing page 47. 3 Disconnect the cabling from sensor hydraulic oil temperature (B776). 4 Change sensor hydraulic oil temperature (B776).

NOTE Check that the O-rings are intact and fitted correctly.

008222

5 Connect the cabling to the sensor.

Sensor hydraulic oil temperature (B776)

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10 Common hydraulics – 10.6.5 Radiator bypass valve

6 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.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted. 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.

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10 Common hydraulics – 10.6.5 Radiator bypass valve

41

Cooler bypass valve, replacement

page –

NOTE Read the safety instructions for oil before working, see section B 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. 2 Depressurising removed. 3 Drain the oil from the hydraulic oil tank; see Hydraulic oil, changing page 47. 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 6 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.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

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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.

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Workshop manual DRF 400–450

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.

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page –

10 Common hydraulics – 10.6.7 Oil filter

Hydraulic oil filter, replacement

NOTE Read the safety instructions for oil before working, see section B 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 Turn off the engine and the main electrical power. 2 Remove the cover plates (position 1) over the hydraulic oil filters. 3 Lift up the filter unit and place it in the receptacle. Let the 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 3. Sight glass, hydraulic oil 4. Hydraulic oil filler orifice 5. Breather filter hydraulic oil tank 5 Clean the filter holder’s parts. Be especially thorough with the magnetic rod. 6 Fit the new filters and assemble the filter units. 7 Install the filter units and the covers. Tighten the screws crosswise.

Magnetic rod

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10 Common hydraulics – 10.6.7 Oil filter

45

8 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.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

Hydraulic oil filter (high-pressure filter), replacement

page –

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

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10 Common hydraulics – 10.6.7 Oil filter

10 Close the drain valve on the accumulator charging valve.

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

11 Close the relief valve for top lift.

C AUTION Hydraulic oil may be directed the wrong way. 010475

Risk of damage to the fine filter for hydraulic oil. 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. 12 Turn on the main electric power and start the engine. 13 Check that the filter holders are not leaking. 14 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.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

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Workshop manual DRF 400–450

10 Common hydraulics – 10.6.8 Hydraulic oil

10.6.8 page –

47

Hydraulic oil

Hydraulic oil, changing

NOTE Read the safety instructions for oil before working, see section B 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, see section B Safety. 2 Remove the filler cap and pump out the hydraulic oil into a receptacle. 3 When as much oil as possible has been pumped out. Place a receptacle under the hydraulic oil tank’s drain plug and drain the last of the hydraulic oil. 4 Fit the drain plug when the oil has drained. 1. Oil filter cover 2. Hydraulic oil filler orifice 3. Sight glass, hydraulic oil 4. Hydraulic oil filler orifice 5. Breather filter hydraulic oil tank

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.

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page –

10 Common hydraulics – 10.6.10 Pipes and hoses

Hydraulic oil fine filter, replacement

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

I M P OR TA NT Make sure that the area around the filter is clean when working. Dirt particles may cause machine damage. 1 Machine in service position, see section B Safety. 2 Remove the cover. 3 Lift up the filter insert 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.

5 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.

C AUTION Overfilling of oil, leakage, and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

10.6.10 page –

Pipes and hoses

Pipes and hoses, general See Pipes and hoses, general page 31.

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Workshop manual DRF 400–450

10 Common hydraulics – 10.7 Auxiliaries

10.7 10.7.1 page –

49

Auxiliaries Hydraulic cylinders

Hydraulic cylinders, repairs 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.

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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.

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10 Common hydraulics – 10.7.1 Hydraulic cylinders

51

Function and removal of the seals Piston rod seal

2

The piston rod seal is the seal that sits in the groove in the cylinder head and seals against the piston rod. This seal is 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:

1

3

001497

4

6

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

1

•

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

6

Single V-ring seal

The pretensioned V seal also has an O-ring in the seal’s V-shaped space. The O-ring creates a strong seal at low hydraulic pressure since the O-ring already presses the sealing lips out toward the sealing surfaces when unloaded. It is just as sensitive to damage as the V seal. Examine in the same manner. To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). It is extremely important that the screwdriver is always inserted in the V shape so that it cannot touch and thereby damage a sealing surface. A mark from a screwdriver on a sealing surface can have a devastating effect and cause major leakage.

2

7

•

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 7. O-ring

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10 Common hydraulics – 10.7.1 Hydraulic cylinders

The compressible piston rod seal consists of a solid rubber profile and provides a larger sealing surface than the V seals. To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). With this type of seal with sealing surfaces that cover so much of the seal groove, it is particularly important that marks are not made with the screwdriver.

2 1 3

3 6

4

001499

5

5 1. Hydraulic pressure 2. 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

Thrust ring and O-ring The thrust ring and O-ring combination is used for sealing between two fixed surfaces, such as between cylinder barrel and cylinder head. The purpose of the thrust ring is to lend rigidity to the O-ring so that it is not deformed. The O-ring is pressed against the thrust ring and the sealing surface by the hydraulic pressure in the cylinder.

3

When the cylinder head is mounted in the barrel: Take extreme care not to damage the O-ring.

4

1

001506

2

1. Hydraulic pressure 2. O-ring 3. Thrust ring 4. Sealing surface, cylinder head

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Workshop manual DRF 400–450

10 Common hydraulics – 10.7.1 Hydraulic cylinders

53

Scraper

øD+10 1

The purpose of the scraper is to scrape the piston rod clean and prevent impurities from entering the cylinder barrel.

2

The scraper 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.

4

To prevent the scraper from bottoming in its recess in the cylinder head, the recess is slightly deeper than the width of the scraper.

3 øD 5

001496

6

1. Correct assembly tool 2. Scraper, correctly fitted 3. Cylinder head 4. Clearance between scraper and bottom of cylinder head 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

3

1. Screwdriver 2. Scraper 3. Cylinder head

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10 Common hydraulics – 10.7.1 Hydraulic cylinders

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.

2

1

To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). It is extremely important that the screwdriver is 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

002370

4

6

5 1. Hydraulic pressure 2. Seal pressed out toward cylinder barrel 3. Seal pressed in toward piston 4. Sealing surface, cylinder barrel 5. Sealing surface. piston 6. Screwdriver

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.

5

4

3

1

Double-acting piston seal

6

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

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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.

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10 Common hydraulics – 10.7.1 Hydraulic cylinders

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

1

2

A small impact mark on a piston rod may be sufficient to cause leakage. The chromium plating on the piston rod has a thickness of 20-50 micrometres and can be treated to make good minor damage. This may be a satisfactory alternative to costly disassembly.

3

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.

4

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

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10 Common hydraulics – 10.7.1 Hydraulic cylinders

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

Workshop manual DRF 400–450

11 Common electrics

1

11 Common electrics

Table of Contents 11 Common electrics mm mm mm mm mm mm

11 Common electrics .......................................................................................... 3 11.2 Electric protection ....................................................................................... 3 11.2.1 Battery 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

Workshop manual DRF 400–450

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11 Common electrics

Workshop manual DRF 400–450

11 Common electrics

3

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 machine’s electrical system via the battery disconnect switch. The battery disconnector cuts off all power from the batteries to the machine’s electrical system.

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.

A

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.

Workshop manual DRF 400–450

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11 Common electrics – 11.3 Batteries

11.3 11.3.1

Batteries Start battery

Start battery, description

page –

The machine’s electrical system is supplied by two 12 V batteries connected in series. The negative terminal is connected to the frame. The positive terminal is connected to the battery disconnector. The batteries are charged by the alternator, see Alternator, description (engine alternative 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

Workshop manual DRF 400–450

11 Common electrics – 11.3.1 Start battery

5

Starter battery, replacement

page –

1 Machine in service position, see section B Safety. 2 Disconnect the cables from the battery terminals, starting with the negative (minus) cable. 3 Replace the batteries. 4 Connect the cables to the battery terminals. Connect the negative cable last of all.

NOTE

000269

Take great care when reconnecting the cables to prevent short circuiting.

Workshop manual DRF 400–450

VDRF03.02GB

6

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 See supplier documentation, engine.

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5 Distribution of electricity

11.5

7

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

1

2

3

D1

-

D3

D2

+

4

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

1

The NC switch, operator’s 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 cab control unit (D790-1).

-

The switch for warning lights (S109) sends a voltage signal to the cab control unit (D790-1).

U = 24 V

When the ignition (S150) is turned to position I, it sends a voltage signal to the cab control unit (D790-1).

U = 24 V

The cab control unit (D790-1) activates a hold circuit, which activates the control unit’s control logic.

-

2

3

4

5

D1: Diagnostic menu, see section 8 Control system, group 8.4.2.12 LIGHTS, menu 12 or 8.4.11.2 SLIDING CAB, menu 1 Section 9 Frame, body, cab and accessories, group 9.6.12 Interior lighting D2: Diagnostic menu, see section 8 Control system, group 8.4.2.12 LIGHTS, menu 12 Section 9 Frame, body, cab and accessories, group 9.6.7 Warning lights D3: Diagnostic menu, see section 8 Control system, group 8.4.2.8 LIGHTS, menu 8 Section 9 Frame, body, cab and accessories, group 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

Workshop manual DRF 400–450

VDRF03.02GB

8

11 Common electrics – 11.5.1.2 Redundant voltage feed of control units

Pos

Explanation

Signal description

Reference

6

The cab control unit (D790-1) activates a redundant voltage feed to other control units.

UK11:7 = 24 V

Cab control unit, description page 19

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.

8

9

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

D7: Diagnostics menu, see section 8 Control system, group 8.4.1.8 CAN/POWER, menu 8

UK2:7 = 24 V

Control unit, frame rear, description page 21

UK2:8 = 24 V

D8: Diagnostics menu, see section 8 Control system, group 8.4.1.10 CAN/POWER, menu 10

UK2:7 = 24 V

Control unit, frame option, description page 22

UK2:8 = 24 V

D9: Diagnostics menu, see section 8 Control system, group 8.4.1.12 CAN/POWER, menu 12

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

D11: Diagnostics menu, see section 8 Control system , group 8.4.1.14 CAN/POWER, menu 14

UK2:7 = 24 V

Attachment control unit, option, description page 24

UK2:8 = 24 V

D12: Diagnostics menu, see section 8 Control system , group 8.4.1.17 CAN/POWER, menu 17

UK2:7 = 24 V

Control unit, attachment left jack pair, description page 25

UK2:8 = 24 V

D13: Diagnostics menu, see section 8 Control system , group 8.4.1.18 CAN/POWER, menu 18 14

UK2:7 = 24 V UK2:8 = 24 V

Control unit, attachment right jack pair, description page 26 D14: Diagnostics menu, see section 8 Control system , group 8.4.1.19 CAN/POWER, menu 19

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5.1.3 Ignition voltage (15)

11.5.1.3

9

Ignition voltage (15)

Ignition voltage (15), description of operation

page –

Condition

Reference value

Reference

Battery disconnector

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

3

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

1

Warning light comes on and sends a voltage signal to the cab control unit (D790-1).

U = 24 V

Section 9 Frame, body, cab and accessories, group 9.6.7 Warning lights

When the start key is turned to position I, it sends a voltage signal to the cab control unit (D790-1).

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

2

3

4

D1: Diagnostic menu, see section 8 Control system , group 8.4.2.8 LIGHTS, menu 8 Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D2: Diagnostics menu, see section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4

Cab control unit, description page 19 D3: Diagnostics menu, see section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4 -

Workshop manual DRF 400–450

VDRF03.02GB

10

11 Common electrics – 11.5.1.3 Ignition voltage (15)

Pos

Explanation

Signal description

Reference

5

The fuses feed voltage to control units, relays, solenoid valves and other electronic components.

U = 24 V

-

6

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

7

Drivetrain’s CAN-bus establishes communication.

Checked by control system, error shown with error code.

Drivetrain CAN bus, description page 48

8

Ignition voltage to the cab control unit (D790-1).

UK1:2 = 24 V

Cab control unit, description page 19

UK1:3 = 24 V

D8: Diagnostics menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6

UK1:4 = 24 V 9

10

Ignition voltage to Control unit, frame rear (D797-R).

UK2:1 = 24 V

Control unit, frame rear, description page 21

UK2:9 = 24 V

D9: Diagnostics menu, see section 8 Control system, group 8.4.1.10 CAN/POWER, menu 10

Ignition voltage to Control unit, frame front (D797-F).

UK2:1 = 24 V

Control unit, frame front, description page 20

UK2:9 = 24 V

D10: Diagnostics menu, see section 8 Control system, group 8.4.1.8 CAN/POWER, menu 8

UK2:10 = 24 V 11

12

Ignition voltage to Control unit, frame option (D797-O).

UK2:10 = 24 V

Ignition voltage to the transmission control unit (D793).

UA1 = 24 V

VDRF03.02GB

Control unit, frame option, description page 22 D11: Diagnostics menu, see section 8 Control system, group 8.4.1.12 CAN/POWER, menu 12

Transmission control unit, description page 27 D12: Diagnostics menu, see section 8 Control system, group 8.4.1.15 CAN/POWER, menu 15

Workshop manual DRF 400–450

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

Redundant voltage feed

Activated

Redundant voltage feed for control units, description of operation page 7

Ignition voltage

Activated

Ignition voltage (15), description of operation page 9

Safety switch

Not activated

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

-

3, 4

6

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

1

Ignition voltage is activated by the cab control unit (D790-1).

Checked by control system, error shown with error code.

Ignition voltage (15), description of operation page 9

2

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

Cab control unit, description page 19

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

3

D2: Diagnostics menu, see section 8 Control system , group 8.4.1.5 CAN/POWER, menu 5

Workshop manual DRF 400–450

Electronic box frame, description page 17 D3: Diagnostics menu, see section 8 Control system , group 8.4.1.5 CAN/POWER, menu 5

VDRF03.02GB

12

11 Common electrics – 11.5.1.4 Emergency stop switch voltage

Pos

Explanation

Signal description

Reference

4

The emergency stop switch voltage relay (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

Electronic box frame, description page 17

UK3009-2/87 = 0 V

D4: Diagnostics menu, see section 8 Control system , group 8.4.1.5 CAN/POWER, 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

Cab control unit, description page 19

The emergency stop switch voltage relay K3009-2 supplies voltage to emergency stop switch circuit.

UK3009-2/87 = 24 V

This verifies that the operation breaker is working. 5

6

VDRF03.02GB

D5: Diagnostics menu, see section 8 Control system , group 8.4.1.5 CAN/POWER, menu 5

Workshop manual DRF 400–450

Electronic box frame, description page 17

11 Common electrics – 11.5.1.4 Emergency stop switch voltage

13

Pos

Explanation

Signal description

Reference

7

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

D7: Diagnostics menu, see section 8 Control system , group 8.4.1.8 CAN/POWER, menu 8

Emergency stop switch in home position: UK2:6

Control unit, frame option, description page 22

= 24 V

D8: Diagnostics menu, see section 8 Control system , group 8.4.1.12 CAN/POWER, menu 12

Emergency stop switch in home position: UK2:1

Control unit, attachment right jack pair, description page 26

= 24 V

D9: Diagnostics menu, see section 8 Control system , group 8.4.1.19 CAN/POWER, menu 19

8

9

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.

Emergency stop switch in home position: UK2:11 = 24 V Emergency stop switch in home position: UK2:1

Control unit, attachment left jack pair, description page 25

= 24 V

D10: Diagnostics menu, see section 8 Control system , group 8.4.1.18 CAN/POWER, menu 18

Emergency stop switch in home position: UK2:11 = 24 V 11

Emergency stop switch in home position: UK2:1

Attachment control unit, option, description page 24

= 24 V

D11: Diagnostics menu, see section 8 Control system , group 8.4.1.17 CAN/POWER, menu 17

Emergency stop switch in home position: UK2:11 = 24 V 12

Emergency stop switch in home position: UK2:1

Attachment control unit, description page 23

= 24 V

D12: Diagnostics menu, see section 8 Control system , group 8.4.1.16 CAN/POWER, menu 16

Emergency stop switch in home position: UK2:9 = 24 V Emergency stop switch in home position: UK2:10 = 24 V Emergency stop switch in home position: UK2:11 = 24 V

Workshop manual DRF 400–450

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 operator’s 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 cab’s electronic box. (Contains both 15, 30-voltage, ground and 12V.)

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5.1.5 Voltage converter

15

Voltage converter, replacement

page –

1 Machine in service position, see section B Safety. 2 Remove the covers behind the driver’s seat. 3 Detach the electrical cables from the converter. 4 Remove the voltage converter. 5 Fit in the reverse order.

The voltage converter is located behind the operator’s seat.

Workshop manual DRF 400–450

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:

6

•

Control unit cab (D790-1)

•

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 •

1

Connector customer accessory. Output voltage 24 V, max. 10 A. Connector 2-pin Universal mate-n-lock. For part number see Spare parts catalogue.

2

NOTE

3

This connector is not on the machine if the machine is equipped with voltage converter.

4

008230

5

1. Control unit cab (D790-1) 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

Workshop manual DRF 400–450

11 Common electrics – 11.5.2.2 Electronic box frame

11.5.2.2

17

Electronic box frame

Electronic box frame, description

page –

1

The electrical distribution box is mounted on the side of the machine. Also located there are:

4

3

2

5 4 F5

6 3

9 D7

8-3

8-2

F5

8-1

F5

F5

9

K1

K3

68

X1

7

•

Circuit fuses

•

Socket for programming transmission control unit (D793)

•

Main fuses

•

Transmission control unit (D793)

•

Power relays for voltage feed to the machine’s functions.

K4 K2

004923

8

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) 8. Power relay (K3009-1) 9. Power relay (K3009-2)

Workshop manual DRF 400–450

VDRF03.02GB

18

11 Common electrics – 11.5.3 Control units

11.5.3

Control units

Control units, position

page –

1

4

3

2

5

6

15

7

13 1. 2. 3. 4. 5. 6. 7. 8. 9.

12

11

Control unit cab (D790-1) Control unit KID (D795) Control unit KIT (D790-2) Control unit, frame front (D797-F)

10 10. 11. 12. 13. .

Frame option control unit (D797-O) Attachment control unit (D791-1)

8

Transmission control unit (D793) Engine control unit (D794) Control unit, frame rear (D797-R) 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

9

Workshop manual DRF 400–450

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.

1

3 2

4

5 6 000041

2

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 unit’s 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 1 Machine in service position. 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 machine’s 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.

Workshop manual DRF 400–450

VDRF03.02GB

20

11 Common electrics – 11.5.3.2 Control unit, frame front

11.5.3.2

1 2 3

6

Control unit, frame front (D797-F) processes input data from sensors and sends control signals to relays and solenoid valves in the machine’s front half. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage.

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 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

Control unit, frame front, description

page –

Red light on at active error.

Control unit, frame front, replacement 1 Machine in service position. 2 Detach the cables from the control unit, frame front (D797-F). 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 Calibrate the new control unit; see section 8 Control system, group 8.5.2.1 Calibrate SCALE (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 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.

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5.3.3 Control unit, frame rear

11.5.3.3

Control unit, frame rear

Control unit, frame rear, description

page –

1 2 3

6

Control unit, frame rear (D797-R) processes input data from sensors and sends control signals to relays and solenoid valves for functions in the machine’s rear half. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage.

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 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 –

21

Red light on at active error.

Control unit, frame rear, replacement 1 Machine in service position. 2 Detach the cables from the control unit, frame rear (D797-R). 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 Calibrate the new control unit; see section 8 Control system, group 8.5.2.1 Calibrate SCALE (length sensor, angle sensor).

Workshop manual DRF 400–450

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

6

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 5. Control signals (inputs and outputs) 6. Power supply (redundant voltage feed for control units, redundant CAN bus) and input data

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 machine’s front half. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. 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 –

Red light on at active error.

Control unit, frame option, replacement 1 Machine in service position. 2 Disconnect the cable harness from the control unit. 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 The control unit is not calibrated.

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5.3.5 Control unit, attachment

11.5.3.5

Control unit, attachment

Attachment control unit, description

page –

1 2 3

6

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. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage.

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 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 –

23

Red light on at active error.

Attachment control unit, replacement 1 Machine in service position. 2 Disconnect the cable harness from the control unit. 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 The control unit is not calibrated.

Workshop manual DRF 400–450

VDRF03.02GB

24

11 Common electrics – 11.5.3.6 Attachment control unit, option

11.5.3.6

Attachment control unit, option

Attachment control unit, option, description

page –

1 2 3

6

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 5. Control signals (inputs and outputs) 6. Power supply (redundant voltage feed for control units, redundant CAN bus) and input data

The attachment control unit, option (D791-2) processes input data from sensors and sends control signals to relays and solenoid valves for optional functions on the top lift attachment. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. 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 –

Red light on at active error.

Attachment control unit, option, replacement 1 Machine in service position. 2 Disconnect the cable harness from the control unit. 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 The control unit is not calibrated.

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5.3.7 Control unit, attachment left jack pair

11.5.3.7

25

Control unit, attachment left jack pair

Control unit, attachment left jack pair, description

page –

1 2 3

6

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 5. Control signals (inputs and outputs) 6. Power supply (redundant voltage feed for control units, redundant CAN bus) and input data

Control unit, attachment left jack pair (D791-3) processes input data from sensors and sends control signals to relays and solenoid valves 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. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. 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

Red light on at active error.

Control unit, attachment left jack pair, replacement

page –

1 Machine in service position. 2 Disconnect the cable harness from the control unit. 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 The control unit is not calibrated.

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

Workshop manual DRF 400–450

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

Control unit, attachment right jack pair, description

page –

1 2 3

6

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 5. Control signals (inputs and outputs) 6. Power supply (redundant voltage feed for control units, redundant CAN bus) and input data

Control unit, attachment right jack pair (D791-4) processes input data from sensors and sends control signals to relays and solenoid valves 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. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. 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

Red light on at active error.

Control unit, attachment right jack pair, replacement

page –

1 Machine in service position. 2 Disconnect the cable harness from the control unit. 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 The control unit is not calibrated.

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

Workshop manual DRF 400–450

11 Common electrics – 11.5.3.9 Control unit transmission

11.5.3.9

27

Control unit transmission

Transmission control unit, description

page –

1

2

The transmission control unit TCU (D793) is part of drivetrain control and handles the transmission’s function, selection of gear at load and engine speed, etc.

3

D

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.

M

E F

S

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 transmission’s direction of rotation

•

VSPD - shows speed in km/h

•

dist - shows distance driven in km or miles

Display group II •

CPOS - shows gear position

•

Tspd - shows measured turbine speed in km/h or mph

•

Espd - shows measured engine speed in rpm

•

Ospd - shows measured speed out from the transmission in rpm

•

Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)

•

TQ I - shows measured torque (Nm) of transmission in

•

Ttmp - shows measured temperature in the oil sump (Celsius or Fahrenheit)

•

Ctmp - shows measured temperature in the converter (Celsius or Fahrenheit)

Display group III •

Err - shows error codes (current and history)

Workshop manual DRF 400–450

VDRF03.02GB

28

11 Common electrics – 11.5.3.10 Control unit, engine

Transmission control unit, replacement

page –

1 Machine in service position. 2 Disconnect the cable harness from the TCU control unit. 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 Calibrate the new control unit; see section 8 Control system, group 8.5.2.3 Calibrate DRIVETRAIN and section 2 Transmission, group 2.8 Control system, transmission.

11.5.3.10

Control unit, engine

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 control unit (D790-1). The cab control unit (D790-1) sends drivetrain information on to other units.

1

3 Control unit, engine 1. Connector 1 (black) 2. Connector 2 (red) 3. Cooling duct for control unit (fuel)

007427

2

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

•

camshaft’s 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

Workshop manual DRF 400–450

11 Common electrics – 11.5.3.10 Control unit, engine

29

Control unit, engine, description (engine alternative Volvo TAD1250VE)

page –

The engine control unit (D794) is part of drivetrain control and handles engine function, fuel injection, etc.

1

The engine control unit (D794) is connected via separate CAN bus communication to the transmission, which is connected to the cab control unit (D790-1). The cab control unit (D790-1) sends drivetrain information on to other units.

2

007424

3

Control unit, engine 1. Cooling duct for control unit (fuel) 2. Connector A (black) 3. Connector B (grey)

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

•

camshaft’s position

•

boost pressure

•

charge-air temperature

•

coolant temperature

•

oil pressure

•

oil temperature

•

oil level

•

crankcase pressure

•

water in fuel

•

fuel pressure

•

coolant level

The data gives exact information about the operating conditions and makes it possible for the control unit to, for example, calculate the correct fuel volume and to check the condition of the engine.

Workshop manual DRF 400–450

VDRF03.02GB

30

11 Common electrics – 11.5.3.11 Control unit KIT

Control unit, engine, description (engine alternative Cummins)

page –

1

2

The engine control unit (D794) is part of drivetrain control and handles engine function, fuel injection, etc.

3

The engine control unit (D794) is connected via separate CAN bus communication to the transmission, which is connected to the cab control unit (D790-1). The cab control unit (D790-1) sends drivetrain information on to other units.

007423

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.

1. Connector OEM 2. Connector, Actuator 3. Connector, Sensor

•

engine rpm

•

boost pressure

•

charge-air temperature

•

coolant temperature

•

oil pressure

•

oil temperature

•

coolant level

•

water in fuel

•

air pressure

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.

Engine control unit, replacement

page –

See supplier documentation, engine.

11.5.3.11

Control unit KIT

KIT control unit, description

page –

1

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).

2

The KIT control unit (D790-2) has several individual function keys and indicator lights (see illustration).

000049

See the operator’s 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

Workshop manual DRF 400–450

11 Common electrics – 11.5.3.12 Control unit KID

31

Control unit KIT, replacement

page –

1 Machine in service position. 2 Remove the steering wheel and open the steering wheel panel. 3 Detach KIT from the steering wheel panel. 4 Detach the connector sockets. 5 Remove the warning panel for warning and indicator lights. 6 Fit in the reverse order. 7 KIT is not calibrated.

11.5.3.12

Control unit KID

KID control unit, description

page –

1

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.

2

There is an indicator light to the right of the display that is activated with a red light when there is a serious malfunction in the control system. The error code and information are shown on the display.

000051

See the operator’s manual for detailed information on the display.

1. LCD display 2. Series of diodes that serve as an indicator light for major error. page –

Control unit KID, replacement 1 Machine in service position. 2 Remove the steering wheel and open the steering wheel panel. 3 Detach the connector from KID. 4 Detach KID from the steering wheel panel. 5 Fit in the reverse order. 6 KID is not calibrated.

Workshop manual DRF 400–450

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

6

000043

4

5

1. Light 1, battery voltage 2. Light 2, redundant voltage feed and power supply 3. Light 3, communication 4. Light 4, error indication 5. Control signals (inputs and outputs) 6. Power supply (redundant voltage feed for control units, redundant CAN bus) and input data

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. The control unit has four indicator lights that indicate the control unit’s 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 one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. 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 –

Red light on at active error.

Control unit cab, option, replacement 1 Machine in service position. 2 Disconnect the cable harness from the control unit. 3 Change control unit. 4 Check that the new control unit matches the machine’s forklift number (Z-number). 5 The control unit is not calibrated.

VDRF03.02GB

Workshop manual DRF 400–450

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

Control unit cab (D790-1)

Power supply and earth connection Control unit cab (D790-1)

X002

Control unit cab (D790-1)

Windscreen wipers Cooling fan Actuator motor, recirculation

X004

Control unit cab (D790-1)

Air conditioning system

X005

Control unit cab (D790-1)

Switch option Switch warning light (Hazard) Air conditioning system Extra sensors Accelerator pedal

X006

Control unit cab (D790-1)

Instrument lighting dimmer Switch work lights Switch option Seat heater Accelerator pedal Brake pedal

X007

Control unit cab (D790-1)

Control lever Indicator light support jacks down

X008

Control unit cab (D790-1)

Control lever Switch, bypass Emergency stop switch Switch, parking brake Switch sliding cab Switch support jacks Switch 30-35 stop Switch option Switch twistlocks

X009

Control unit cab (D790-1)

Combi attachment Overheight Lever steering or mini-wheel

X009A

Extension X009A

Lever steering or mini-wheel

Workshop manual DRF 400–450

VDRF03.02GB

34

11 Common electrics – 11.5.5 Cables

Connector

Location

Function

X010

Control unit cab (D790-1)

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

Control unit cab (D790-1)

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

Control unit cab (D790-1)

Windscreen wiper, rear Windscreen wiper, roof

X013

Control unit cab (D790-1)

CAN-bus RS232

X015

Control unit KIT (D790-2)

CAN-bus Power supply and earth connection, Control unit KIT (D790-2)

X016

Control unit KIT (D790-2)

Ignition switch

X017

Control unit KIT (D790-2)

Control, windscreen wipers Control, gear Control, main and dipped beams

X018

Control unit KIT (D790-2)

Steering angle sensor Switch, direction indicators

X018A

Extension X018

Steering angle sensor

X020

Control unit KID (D795)

CAN-bus RS232 Printer Power supply and earth connection, Control unit KID (D795)

X021

VDRF03.02GB

Control unit cab, option (D790-3)

Lever steering or mini-wheel

Workshop manual DRF 400–450

11 Common electrics – 11.5.5 Cables

35

Connector

Location

Function

X022

Control unit cab, option (D790-3)

Power supply and earth connection Control unit cab, option (D790-3) CAN bus, Control unit, cab option (D790-3)

X033

Air conditioning system

Control, fan Control, temperature Control, air distribution

X034

Air conditioning system

Heater fan Water valve

X035

Air conditioning system

Valve, air distribution Sensor, air temperature

X036

Air conditioning system

Actuator motor, recirculation 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 warning light (Hazard) Switch, cab door Actuator motor, recirculation 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 Flashing hazard lights

X055

Electronic box cab

Windscreen wiper, roof Current, CD player Current, COM radio

Workshop manual DRF 400–450

VDRF03.02GB

36

11 Common electrics – 11.5.5 Cables

Connector

Location

Function

X056

Electronic box cab

Flashing hazard lights Working lights, boom 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

Instrument panel, cab

Switch work lights Switch, main beams Switch, warning lights Switch, seat heater Switch, option

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5.5 Cables

Connector

Location

Function

X081

Instrument panel, cab

Switch, option

37

Switch warning light (Hazard) Extra sensors Hour counter X082

Instrument panel, cab

NC switch, cab door left side

X168

Electronic box frame

Power supply, boom and attachment

X200

Boom mounting

CAN-bus Redundant power supply, control units

X201

Electronic box frame

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 Working lights, boom

X203

Electronic box frame

Termination resistor

X205

Electronic box frame

CAN-bus Transmission control unit (D793)

X206

Boom mounting

Revolving beacon boom Working lights, boom

X210

Between engine and transmission

Power supply and earth connection, Control unit engine (D794) CAN bus, Control unit engine (D794)

X211

Control unit, frame front (D797-F)

42-pin connector to Control unit, frame front (D797-F)

X212

Control unit, frame front (D797-F)

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

Control unit, frame rear (D797-R)

42-pin connector to Control unit, frame rear (D797-R)

Workshop manual DRF 400–450

VDRF03.02GB

38

11 Common electrics – 11.5.5 Cables

Connector

Location

Function

X222

Control unit, frame rear (D797-R)

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

Frame option control unit (D797-O)

42-pin connector to Control unit, frame option (D797-O)

X232

Frame option control unit (D797-O)

Power supply and earth connection, Control unit, frame option (D797-O) CAN bus, Control unit, frame option (D797-O) Safety switch

X233

Frame option control unit (D797-O)

Sensor support jacks Solenoid valve support jacks up and down

X235

Frame option control unit (D797-O)

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

Electronic box frame

Power supply and earth connection Control unit transmission (D793)

X259

Transmission

Temperature sensor, transmission oil for radiator

X260

Electronic box frame

CAN bus, Control unit transmission (D793)

X261

Electronic box frame

RS232 Control unit transmission (D793)

X264

Electronic box frame

Solenoid valve brake transmission

X265

Cab

Reversing camera

X270

Lamp bracket left frame

Main and dipped beams Flashing hazard lights Driving direction indicator Side marker lights

X271

Lamp bracket front

Main and dipped beams Flashing hazard lights Driving direction indicator Side marker lights

VDRF03.02GB

Workshop manual DRF 400–450

11 Common electrics – 11.5.5 Cables

Connector

Location

Function

X272

Lamp bracket left rear

Reversing light

39

Tail light Brake light Driving direction indicator Side marker lights X273

Lamp bracket right rear

Reversing light Tail light Brake light Driving direction indicator 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

Attachment control unit (D791-1)

42-pin connector for attachment control unit (D791-1)

Workshop manual DRF 400–450

VDRF03.02GB

40

11 Common electrics – 11.5.5 Cables

Connector

Location

Function

X412

Attachment control unit (D791-1)

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

Attachment centre section

Rotation stop

X421

Attachment control unit, option (D791-2)

42-pin connector for Control unit, attachment option (D791-2)

X422

Attachment control unit, option (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

Control unit, attachment left jack 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

Control unit, attachment left jack 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

Control unit, attachment right jack 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

Control unit, attachment right jack 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

Workshop manual DRF 400–450

11 Common electrics – 11.5.5 Cables

Connector

Location

Function

X445

Combi attachment, right side rear

Sensor, clamping position right rear jack

41

Sensor, alignment right front jack X489

Attachment centre section

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 machine’s control units use a number of different types of signals to receive signals from sensors and switches and control solenoid valves, lights, etc. The table below describes the different signal types. Signal type

Explanation

Usage area

Rheostat

Resistance input 0–200 Ω. Linear work range with accuracy of 3%.

E.g. fuel level sensor.

Temperature

Rheostat input with non-linear work area. The resistance value is equivalent to temperature and the work range of approx. -40 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 (sensor’s measurement inaccuracy not included). Outside of the interval 0 –100 °C, accuracy is ±2 °C. Voltage

An analogue signal 0–5 V. The work range is 0.5 to 4.5 V.

E.g. accelerator pedal and analogue cab controls (operating lever and heater controls).

A modulated signal between 0 V and system voltage, i.e. 24 V. The work range is 0 to 2 A.

Hydraulics, e.g. lifting/ lowering of the boom.

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 valve’s 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.

Workshop manual DRF 400–450

E.g. interior lighting and background illumination in switches.

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11 Common electrics – 11.5.5 Cables

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.

Digital input signal 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

Logic one (1) generates voltage out, U >= 22.5 V Max. load 5 A

E.g. work lighting and wiper motors.

Open load 0.9 A Max. instantaneous current load, 35 A High side driver, 10 A

Logic one (1) generates voltage out, U >= 22.5 V

E.g. cooling fan.

Max. load 10 A

This output is only found on the frame and attachment control units.

Open load 1.9 A Max. instantaneous current load, 70 A H-bridge

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 Max. instantaneous current load, 8 A The H-bridge works with two outputs in a pair. At logic one (1), one output gives voltage while the other output is grounded. At logic zero (0), the outputs switch voltage levels.

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Workshop manual DRF 400–450

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 –

1

2

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

5

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.

2

000026

3 t [S] Messages are sequential and signal is high (voltage high) or low (voltage low). 1. Termination resistor (120 ohm) 2. CAN + (voltage high) 3. CAN - (voltage low) 4. Pulse 5. Control unit

Message There are two types of messages:

B

C

D

E

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

A

•

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.

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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:

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•

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

Workshop manual DRF 400–450

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 machine’s 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 machine’s 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.

Workshop manual DRF 400–450

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11 Common electrics – 11.6.2 Redundant CAN bus

Connection of redundant CAN bus Condition

Reference value

Reference

Battery disconnector

In position 1

Battery disconnector, description page 3

Redundant voltage feed

Activated.

Redundant voltage feed for control units, description of operation page 7

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

4

8

S4

D791-4 5 013023

7

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

1

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.

Cab control unit, description page 19

The attachment control unit (D791-1) 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.

2

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 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

Termination resistors in the control nodes ensure communication segment by segment.

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11 Common electrics – 11.6.2 Redundant CAN bus

47

Pos

Explanation

Signal description

Reference

3

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 termination resistor is activated.

Attachment control unit, option, description page 24

Termination resistors in the control nodes ensure communication segment by segment. 4

Control unit, attachment left jack pair (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 termination resistor is activated.

Termination resistors in the control nodes ensure communication segment by segment. 5

Control unit, attachment right jack pair (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 termination resistor is activated.

Termination resistors in the control nodes ensure communication segment by segment. 6

Control unit, frame rear (D797-R) 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

Control unit, attachment left jack pair, description page 25 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

Control unit, attachment right jack pair, description page 26 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

Control unit, frame rear, description page 21 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

Termination resistors in the control nodes ensure communication segment by segment. 7

Control unit, frame option (D797-O) 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.

Control unit, frame option, description page 22 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

Termination resistors in the control nodes ensure communication segment by segment. 8

Control unit, frame front (D797-F) 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.

Control unit, frame front, description page 20 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

Termination resistors in the control nodes ensure communication segment by segment.

Workshop manual DRF 400–450

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11 Common electrics – 11.6.3 CAN bus drivetrain

Pos

Explanation

Signal description

Reference

9

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 termination resistor is activated.

KID control unit, description page 31

Termination resistors in the control nodes ensure communication segment by segment.

Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

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 termination resistor is 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.

Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

If a control unit has not responded, 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 –

4

D790-1

The drivetrain CAN bus is based on the SAE J1939 standard where selected messages are used to control engine and transmission.

6

3

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.

5

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.

1

2

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

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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.

1

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.

2

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 Volvo’s diagnostic tool - VODIA. The socket for transmission control unit (D793) programming in the frame electronic box (position 4) is used to program the transmission control unit (D793). For further details on communication between computer and machine, contact Cargotec.

3

006887

4

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

Workshop manual DRF 400–450

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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 machine’s position. Control unit CAN gateway RMI (D795-2) sends some information from the machine’s 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)

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11 Common electrics – 11.6.6 Kalmar CAN Customer Gateway

11.6.6

51

Kalmar CAN Customer Gateway

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 machine’s 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

Workshop manual DRF 400–450

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11 Common electrics – 11.6.6 Kalmar CAN Customer Gateway

Workshop manual DRF 400–450

D Error codes

1

D Error codes

Table of Contents D Error codes mm mm mm mm mm mm

D

Error codes ..................................................................................................... 3 Error codes, explanation ........................................................................................ 3 Error code menu, description ................................................................................. 4 Reading out error code ........................................................................................... 7

1

Engine ............................................................................................................. 9 Error codes engine, general ................................................................................... 9 Error codes engine (engine alternative Volvo) ..................................................... 10 Engine error codes (engine alternative Cummins QSM11) .................................. 27

2

Transmission................................................................................................ 39 Error codes, transmission .................................................................................... 39

8

Control system ............................................................................................. 91 Error codes machine ............................................................................................ 91

Workshop manual DRF 400–450

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D Error codes

Workshop manual DRF 400–450

D Error codes – D Error codes

3

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:

C

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

D

•

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.

Workshop manual DRF 400–450

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D Error codes – D Error codes

Error code menu, description

page –

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

C D

E 000389

B

•

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. •

C

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

D

The error code is shown automatically on the display. •

C E

The error code is shown automatically on the display.

•

C E 000352

D

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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

D

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 Operator’s manual. The error code is stored in the error code list under operating menu for service.

Workshop manual DRF 400–450

D Error codes – D Error codes

5

Field C: Error code number The control system gives error codes from three sub-systems: •

C

Machine: Shown with error code number XXX on display.

D

E 000389

B

• XX/YY

Engine: Shown with error code number XXX/YY on display.

D

NOTE If several error codes come from the engine, the error code level is shown for the most serious error code.

001343

B

• XXX/YY

Transmission: Shown with error code number XX/YY on display.

D 001344

B

Field D: Type of error

1

4

2

5

3

6

1.

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

7

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D Error codes – D Error codes

Field E: Affected function

1

4

7

2

3

5

6

8

9

1.

Attachment

2.

Rotation of attachment

3.

Side shift of 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. 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

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D Error codes – D Error codes

7

Reading out error code

page –

NOTE In case of an error code, perform the actions recommended in the error code table to find the problem. Error codes are stored as active and inactive. Active errors are shown in the error code menu. Always use error code menus for reading out error codes, 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.

Workshop manual DRF 400–450

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D Error codes – D Error codes

5 Note error code number (field C) to not forget.

C

B

E 000389

D

•

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 operator’s manual.

6 Use the error code tables to find more information about the error code. 7 After action, check that no active error codes remain for the function in question.

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D Error codes – 1 Engine

9

1 Engine

mm mm mm mm mm mm

Error codes engine, general

page –

When contacting engine suppliers, use Volvo/Cummins codes. •

Display indicates error code according to SAE J1939 SPN/FMI

•

J1587 indicates error code according to SAE J1587 (for Volvo: Vodia). PID, PPID, SID, PSID/FMI

Table 1. Specification FMI

FMI

Description

SAE-text

0

Too high value.

Valid data, but higher than normal operating range.

1

Too low value.

Valid data, but lower than normal operating range.

2

Incorrect data.

Intermittent or incorrect data.

3

Electrical problem.

Abnormally high voltage or short-circuiting to higher voltage.

4

Electrical problem.

Abnormally low voltage or short-circuiting to lower voltage.

5

Electrical problem.

Abnormally low current or open circuit.

6

Electrical problem.

Abnormally high current or short-circuiting to frame ground.

7

Mechanical problem.

Incorrect response from mechanical system.

8

Mechanical problem or electrical problem.

Abnormal frequency.

9

Communication error.

Abnormal update rate.

10

Mechanical problem or electrical problem.

Abnormally wide variations.

11

Unknown malfunction.

Non-identifiable error.

12

Component error.

Defective unit or component.

13

Incorrect calibration.

Values outside calibration values.

14

Unknown malfunction.

Special instructions.

15

Unknown malfunction.

Reserved for future use.

Workshop manual DRF 400–450

VDRF03.02GB

10

D Error codes – 1 Engine

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.

-

-

-

-

Check cabling between control unit and component.

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 feed’s 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.

Check cabling between control unit and component.

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

Workshop manual DRF 400–450

D Error codes – 1 Engine

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.

Check cabling between 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.

Check cabling between 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.

Check cabling between control unit and component.

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 more than normal during acceleration or under load.

Check cabling between control unit and component.

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.

Workshop manual DRF 400–450

VDRF03.02GB

12

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

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.

Check cabling between control unit and component.

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 more than normal during acceleration or under load.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:3

Check the sensor.

Volvo TAD1250VE: D794/A:22

Boost pressure too high.

No limitation.

Check cabling between control unit and component.

-

ENGINE, menu 6

-

ENGINE, menu 7

Check cabling between control unit and component.

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 coolant level. Check that radiator is clean. Check thermostat. Check the cap on the expansion tank. Check if there’s 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.

Workshop manual DRF 400–450

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

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.

-

-

Check cabling between control unit and component.

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 cabling between control unit and component. Check the sensor.

Check and charge the batteries. Check the alternator. Check the battery cables.

Workshop manual DRF 400–450

VDRF03.02GB

14

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:2

ENGINE, menu 7

Check the sensor.

Volvo TAD1250VE: D794/A:47

High engine oil temperature.

Reduced engine power.

Check oil level.

-

ENGINE, menu 7

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:1

ENGINE, menu 7

Check the sensor.

Volvo TAD1250VE: D794/A:31, B:3, B:4

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:1

Check the sensor.

Volvo TAD1250VE: D794/A:31, B:3, B:4

Check the lubrication system’s 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.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:5

-

1079/2

Reduced engine power. Incorrect instrument values.

VDRF03.02GB

Workshop manual DRF 400–450

Volvo TAD1250VE: D794/B:17

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:4

-

J1587 SID232/4

1079/3

Reduced engine power.

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.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/2:36

ENGINE, menu 5

Check the relay.

Volvo TAD1250VE: D794/B:25

Check cabling between control unit and component.

Volvo TWD1240VE: D794/2:36

Check the relay.

Volvo TAD1250VE: D794/B:25

Check cabling between control unit and component.

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.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:7, 1:18

-

Check the sensor.

Volvo TAD1250VE: D794/B:45, B:46

Workshop manual DRF 400–450

VDRF03.02GB

16

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

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.

Check cabling between control unit and component.

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.

Engine is extremely difficult to start and runs rough, if it starts.

Check cabling between control unit and component. 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.

Engine is extremely difficult to start and runs rough, if it starts.

Engine off: engine cannot be started. Engine on: engine goes to idle and can only be stopped by using the emergency stop.

Check cabling between control unit and component. Check that the sensor is connected correctly.

Use diagnostic menu to find incorrect segment. Check cabling between control unit and component. Check the control unit.

Workshop manual DRF 400–450

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

D Error codes – 1 Engine

Code

J1587

639/FMI

SID231/ FMI

17

Description

Limitation

Action

Connections and components

Diagnostic menu

Communication error with Engine control unit (D794), configuration error.

Instruments and controls do not work.

Use diagnostic menu to find incorrect segment.

-

CAN/ POWER, menu 3

Check cabling between control unit and component. Check the control unit.

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.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:11, 1:12

-

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

651/3

651/4

651/5

SID1/3

SID1/4

SID1/5

Electric failure, injector cylinder 1.

Electric failure, injector cylinder 1.

Electric failure, injector cylinder 1.

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.

Workshop manual DRF 400–450

Volvo TWD1240VE: D794/1:11, 1:12

-

Volvo TAD1250VE: D794/A:20, A:24

VDRF03.02GB

18

D Error codes – 1 Engine

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 cabling between control unit and component. 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

Electric failure, injector cylinder 1.

Electric failure, injector cylinder 1.

Electric failure, injector cylinder 1.

Electric failure, injector cylinder 1.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

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.

Workshop manual DRF 400–450

Volvo TWD1240VE: D794/1:22, 1:12 Volvo TAD1250VE: D794/A:12, A:16

-

D Error codes – 1 Engine

Code 652/5

652/7

Description

Limitation

Action

Connections and components

Diagnostic menu

Electric failure, injector cylinder 1.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:22, 1:12

-

Runs rough at low rpm and low load.

Check fuel pressure.

J1587 SID2/5

SID2/7

Incorrect compression or defective injector cylinder 2.

Check the injector.

Volvo TAD1250VE: D794/A:12, A:16

Check valve clearance. Check cabling between control unit and component. Check the injector. Perform compression test and check cylinder 2.

652/11

653/2

653/3

19

SID2/11

SID3/2

SID3/3

Electric failure, injector cylinder 2.

Electric failure, injector cylinder 3.

Electric failure, injector cylinder 3.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

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.

Workshop manual DRF 400–450

Volvo TWD1240VE. D794/1:23, 1:12

-

Volvo TAD1250VE: D794/A:28, A:32

VDRF03.02GB

20

D Error codes – 1 Engine

Code 653/4

653/5

653/7

Description

Limitation

Action

Connections and components

Diagnostic menu

Electric failure, injector cylinder 3.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:23, 1:12

-

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Runs rough at low rpm and low load.

Check fuel pressure.

J1587 SID3/4

SID3/5

SID3/7

Electric failure, injector cylinder 3.

Incorrect compression or defective injector cylinder 3.

Check the injector.

Volvo TAD1250VE: D794/A:28, A:32

Check the injector.

Check valve clearance. Check cabling between control unit and component.

Perform compression test and check cylinder 3.

654/2

VDRF03.02GB

SID3/11

SID4/2

Electric failure, injector cylinder 3.

Electric failure, injector cylinder 4.

-

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.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

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.

Workshop manual DRF 400–450

Volvo TWD1240VE: D794/1:34, 1:24 Volvo TAD1250VE: D794/A:52, A:56

-

D Error codes – 1 Engine

Code 654/3

654/4

654/5

654/7

Description

Limitation

Action

Connections and components

Diagnostic menu

Electric failure, injector cylinder 4.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:34, 1:24

-

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Runs rough at low rpm and low load.

Check fuel pressure.

J1587 SID4/3

SID4/4

SID4/5

SID4/7

Electric failure, injector cylinder 4.

Electric failure, injector cylinder 4.

Incorrect compression or defective injector cylinder 4.

Check the injector.

Volvo TAD1250VE: D794/A:52, A:56

Check the injector.

Check the injector.

Electric failure, injector cylinder 4.

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

Check valve clearance. Check cabling between control unit and component.

Perform compression test and check cylinder 4. SID4/11

Volvo TWD1240VE: D794/1:34, 1:24 Volvo TAD1250VE: D794/A:52, A:56

Check the injector.

654/11

21

Check cabling between control unit and component. Check the injector.

Workshop manual DRF 400–450

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

D Error codes – 1 Engine

Code 655/2

655/3

655/4

655/5

655/7

Description

Limitation

Action

Connections and components

Diagnostic menu

Electric failure, injector cylinder 5.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:35, 1:24

-

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

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

Electric failure, injector cylinder 5.

Electric failure, injector cylinder 5.

Electric failure, injector cylinder 5.

Incorrect compression or defective injector 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 cabling between control unit and component. Check the injector. Perform compression test and check cylinder 5.

VDRF03.02GB

Volvo TWD1240VE: D794/1:35, 1:24

Workshop manual DRF 400–450

Volvo TWD1240VE: D794/1:35, 1:24 Volvo TAD1250VE: D794/A:44, A:48

-

D Error codes – 1 Engine

Code 655/11

656/2

656/3

656/4

656/5

23

Description

Limitation

Action

Connections and components

Diagnostic menu

Electric failure, injector cylinder 5.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:35, 1:24

-

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

J1587 SID5/11

SID6/2

SID6/3

SID6/4

SID6/5

Electric failure, injector cylinder 6.

Electric failure, injector cylinder 6.

Electric failure, injector cylinder 6.

Electric failure, injector cylinder 6.

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.

Workshop manual DRF 400–450

Volvo TWD1240VE: D794/1:36, 1:24

-

Volvo TAD1250VE: D794/A:36, A:40

VDRF03.02GB

24

D Error codes – 1 Engine

Code 656/7

Description

Limitation

Action

Connections and components

Diagnostic menu

Incorrect compression or defective injector cylinder 6.

Runs rough at low rpm and low load.

Check fuel pressure.

Volvo TWD1240VE: D794/1:36, 1:24

-

J1587 SID6/7

Check valve clearance. Check cabling between control unit and component. Check the injector. Perform compression test and check cylinder 6.

656/11

677/FMI

SID6/11

PPID3/ FMI SID39/ FMI

1485/3

2017/ FMI

VDRF03.02GB

PPID5/3

PSID201 /FMI

Electric failure, injector cylinder 6.

Starter motor relay, short circuit to voltage/ground.

Main relay, cable short circuited to voltage.

Communication error with Engine control unit (D794), configuration error.

Volvo TAD1250VE: D794/A:36, A:40

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

The engine will not start.

Check cabling between control unit and component.

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.

Check cabling between control unit and component.

Volvo TWD1240VE: D794/1:32

Check the relay.

Volvo TAD1250VE: D794/A:8

Engine off: engine cannot be started.

Use diagnostic menu to find incorrect segment.

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

Check cabling between control unit and component. Check the control unit.

Workshop manual DRF 400–450

Volvo TAD1250VE: D794/B:51, B:55

ENGINE, menu 5

-

CAN/ POWER, menu 3

D Error codes – 1 Engine

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.

The engine control unit limits engine output. IEGR cannot be activated.

The engine control unit limits engine output. IEGR cannot be activated.

Contact an authorised Volvo Penta workshop. Check the component (IEGR). Check the wiring (boost pressure sensor). Contact an authorised Volvo Penta workshop. Check the component (IEGR). Check the wiring (boost pressure sensor). Contact an authorised Volvo Penta workshop. Check the component (IEGR).

Could damage the turbine wheel of the turbocharger and increase force and emissions.

Check the wiring (boost pressure sensor).

No limitation.

Check cabling between control unit and component.

Contact an authorised Volvo Penta workshop. Check the component (IEGR).

Check the sensor.

Workshop manual DRF 400–450

VDRF03.02GB

26

D Error codes – 1 Engine

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 (-).

Engine starts immediately when the ignition is switched on. Engine cannot be started. Engine starts immediately when 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

Workshop manual DRF 400–450

Volvo TWD1240VE: D794/2:6

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

-

-

Electrical error, speed sensor, signal manipulation detected.

Engine speed is limited to maximum rpm without gear.

Check cabling between control unit and component.

-

-

Electrical error, accelerator pedal, cable short circuited to supply voltage.

Engine does not respond to throttle.

Check cabling between control unit and component.

-

-

Electrical error, accelerator pedal, cable short circuited to ground.

Engine does not respond to throttle.

-

-

Electrical error, accelerator pedal, low frequency.

Engine does not respond to throttle.

-

-

-

-

J1587 PID084/2

PID084/ 10

PID091/3

PID091/4

PID091/8

Check the sensor.

Check the sensor.

Check the component. Check cabling between control unit and component. Check the component. Check cabling between control unit and component. Check the component.

91/8

PID091/8

Electrical error, accelerator pedal, high frequency.

Engine does not respond to throttle.

Check cabling between control unit and component. Check the component.

91/19

SID091/2

Communication error with cab control unit (D790-1), electrical error, accelerator pedal.

Engine will only idle.

Use diagnostic menu to find incorrect segment.

-

CAN/ POWER, menu 3

97/3

PID097/3

Electrical error, water-in-fuel sensor, cable short circuited to supply voltage.

No limitation.

Check cabling between control unit and component.

D794/Sensor:09

-

Check the component.

Workshop manual DRF 400–450

VDRF03.02GB

28

D Error codes – 1 Engine

Code 97/4

Description

Limitation

Action

Connections and components

Diagnostic menu

Electrical error, water-in-fuel sensor, cable short circuited to ground.

No limitation.

Check cabling between control unit and component.

D794/Sensor:09

-

J1587 PID097/4

Check the component.

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, cable short circuited to supply voltage.

No warning of low engine oil pressure.

Check cabling between control unit and component.

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 engine oil pressure.

Check cabling between control unit and component. 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 cabling between control unit and component. Check the sensor.

Check cabling between control unit and component. Check the sensor.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

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.

Check the component.

-

-

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 cabling between control unit and component. 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.

Check cabling between control unit and component. Check that the sensor is 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

Electrical error, air pressure sensor, cable short circuited to supply voltage.

Reduced engine power.

Check cabling between control unit and component.

D794/Sensor:06

-

Check the sensor.

Workshop manual DRF 400–450

VDRF03.02GB

30

D Error codes – 1 Engine

Code 108/4

110/0

Description

Limitation

Action

Connections and components

Diagnostic menu

Electrical error, air pressure sensor, cable short circuited to ground.

Reduced engine power.

Check cabling between control unit and component.

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 coolant level. Check that radiator is clean. Check if there’s 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.

Check cabling between 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.

Check cabling between control unit and component.

D794/Sensor:02

ENGINE, menu 7

-

-

D794/Sensor:09

-

-

-

Check that the sensor is connected correctly. 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 cabling between control unit and component.

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.

Workshop manual DRF 400–450

D Error codes – 1 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

Low battery voltage.

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.

Check batteries and alternator.

D794/ OEM:7, 8, 17, 18, 28

-

168/16

PID168/0

High voltage supply to control unit.

No limitation.

Check fuses. Check batteries and alternator.

D794/ OEM:7, 8, 17, 18, 28

-

168/18

PID168/1

Low voltage supply to control unit.

Uneven idling.

Check fuses. Check batteries and alternator.

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 circuited to ground.

No indication of engine oil temperature.

Check cabling between control unit and component. Check that the sensor is connected correctly. Check cabling between control unit and component. Check the sensor.

Workshop manual DRF 400–450

VDRF03.02GB

32

D Error codes – 1 Engine

Code 188/4

Description

Limitation

Action

Connections and components

Electrical error, wastegate solenoid valve 1 short circuited to ground.

Reduced engine power.

Check cabling between control unit and component.

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.

Check cabling between control unit and component.

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 cabling between control unit and component. 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 circuited to ground.

No warning of high temperature, Control unit, engine (D794).

Check cabling between control unit and component.

D794/Sensor: 12

Auxiliary temperature sensor short circuited to supply voltage.

No warning of high temperature, Control unit, engine (D794).

Check cabling between control unit and component.

Electrical error, accelerator pedal sensor, idling contact, data error.

No limitation.

Check cable between control unit and component.

441/4

558/2

VDRF03.02GB

PID441/4

SID230/2

Check the sensor. D794/Sensor: 12

Check the sensor.

Check component.

Workshop manual DRF 400–450

D794/ OEM: 03, 13

-

D Error codes – 1 Engine

Code 558/4

558/13

33

Description

Limitation

Action

Connections and components

Diagnostic menu

Electrical error, accelerator pedal sensor, idling contact cable short circuited to ground.

Engine does not respond to throttle.

Check cable between control unit and component.

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 control unit and component. Check component.

608/2

SID250/2

Communication error with Control unit engine (D794).

No limitation.

Check the control unit.

D794/ OEM: 26, 27, 36, 37, 46

608/9

SID250/9

Communication error with Control unit engine (D794).

No limitation.

Check the control unit.

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.

Check cabling between control unit and component.

D794/Sensor: 18, 25, 45

-

Electrical error, reference voltage to sensor short circuited to ground.

Reduced engine output. No warning of low oil pressure or low coolant level.

Check cabling between control unit and component.

D794/Sensor: 18, 25, 45

-

Electrical error to control of preheating relay.

Preheating not working. Risk of white smoke.

Check cabling between control unit and component.

D794/Actuator: 34

ENGINE, menu 5

-

1080/3

620/4

SID232/4

1081/4

626/11

SID237/ 11

Check the control unit.

Check the component.

Check the component. 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. Check batteries and alternator.

D794/ OEM:7, 8, 17, 18, 28

629/12

SID254/ 12

Internal error, Control unit, engine.

The engine will not start.

Check the control unit.

-

-

629/12

SID254/ 12

Internal error, Control unit, engine.

No limitation.

Check the control unit.

-

-

Workshop manual DRF 400–450

VDRF03.02GB

34

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

D794/Actuator: 33

-

Electrical error, fuel cut-off solenoid valve, cable short circuited to ground.

Engine will shut down.

D794/Actuator: 33

-

632/4

SID017/4

Check the solenoid valve. Check cabling between control unit and component. Check the solenoid valve.

639/2

SID231/2

Communication error with Control unit engine (D794).

Functions via CAN bus not working.

Use diagnostic menu to find incorrect segment.

-

CAN/ POWER, menu 2

639/9

SID231/9

Communication error with Control unit engine (D794).

Functions via CAN bus not working.

Use diagnostic menu to find incorrect segment.

-

CAN/ POWER, menu 2

639/9

SID231/9

Communication error with Control unit, engine (D794), timeout error.

Functions via CAN bus not working.

Use diagnostic menu to find incorrect segment.

-

CAN/ POWER, menu 2

639/13

SID231/ 13

Communication error with Engine control unit (D794), configuration error.

Functions via CAN bus not working.

Use diagnostic menu to find incorrect segment.

-

CAN/ POWER, menu 2

644/2

SID030/2

Electrical error, accelerator pedal, signal not within valid interval.

Engine will shut down.

Check cabling between control unit and component.

-

-

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 component. Check cabling between control unit and component. Check the component. Check cabling between control unit and component. Check the injector.

Workshop manual DRF 400–450

D Error codes – 1 Engine

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 rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator:10, Actuator: 9

-

Electrical error, cylinder 2 injector, open circuit on cable.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator: 7, 8

-

Electrical error, cylinder 2 injector, cable short circuited to ground.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator:7, 8

-

Electrical error, cylinder 3 injector, open circuit on cable.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator:6, 16

-

Electrical error, cylinder 3 injector, cable short circuited to ground.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cable between control unit and component.

D794/Actuator:6, 16

-

Electrical error, cylinder 4 injector, open circuit on cable.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator:26, 36

-

Electrical error, cylinder 4 injector, cable short circuited to ground.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator:26, 36

-

Electrical error, cylinder 5 injector, open circuit on cable.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator: 3, 4

-

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cable between control unit and component.

D794/Actuator: 3, 4

-

J1587 SID001/7

SID002/5

SID002/6

SID003/5

SID003/6

SID004/5

SID004/6

SID005/5

SID005/6

Electrical error, cylinder 5 injector, cable 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.

Workshop manual DRF 400–450

VDRF03.02GB

36

D Error codes – 1 Engine

Code 656/5

656/6

702/3

974/3

974/4

Limitation

Action

Connections and components

Diagnostic menu

Electrical error, cylinder 6 injector, open circuit on cable.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cable between control unit and component.

D794/Actuator: 1, 2

-

Electrical error, cylinder 6 injector, cable short circuited to ground.

Engine runs on 5 cylinders, sounds rough and has reduced power.

Check cabling between control unit and component.

D794/Actuator: 1, 2

-

Electrical error, auxiliary output 2, cable short circuited to supply voltage.

No limitation.

Check cabling between control unit and component.

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 respond to throttle.

D794/ OEM: 21

-

Electrical error, auxiliary accelerator pedal, cable short circuited to ground.

Engine does not respond to throttle.

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.

Check the component. Check cabling between control unit and component. Check the component. Check cabling between control unit and component. Check the component. Check cabling between control unit and component. Check the component.

974/19

SID029/2

Communication error with cab control unit (D790-1), electrical error, accelerator pedal.

Engine does not respond to throttle.

Use diagnostic menu to find incorrect segment.

-

CAN/ POWER, menu 2

1043/3

PID221/3

Electrical error, accelerator pedal reference voltage, cable short circuited to supply voltage.

Engine will only idle.

Check cabling between control unit and component.

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

Check the component. Check cabling between control unit and component. Check the component.

Workshop manual DRF 400–450

D Error codes – 1 Engine

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.

Check cabling between control unit and component.

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 cabling between control unit and component. 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

Electrical error, reference voltage to sensor short circuited to supply voltage.

Reduced engine power.

Electrical error, reference voltage to sensor short circuited to 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 circuited to ground.

Reduced engine power.

Electrical error, oilburn solenoid valve, cable short circuited to ground.

No limitation.

Check cabling between control unit and component. Check the sensor. Check cabling between control unit and component. Check the sensor. Check cabling between control unit and component. Check the solenoid valve. Check cabling between control unit and component.

D794/Actuator: 23

Check the solenoid valve. Check cabling between control unit and component.

D794/Actuator: 23

Check the solenoid valve. Check cabling between control unit and component.

-

-

Check the solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

38

Code 1319/2

D Error codes – 1 Engine

Description

Limitation

Action

Connections and components

Diagnostic menu

Electrical error, boost pressure sensor.

Reduced engine power.

Check cabling between control unit and component.

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, cable short circuited to supply voltage.

No pressure guard (customer-specific option).

Check cabling between control unit and component.

D794/Sensor: 19

-

Electrical error, auxiliary pressure sensor, cable short circuited 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 cabling between control unit and component. Check the sensor. Check error codes for other machine control units, particularly the cab control unit (D790-1) and transmission control unit (D793).

Workshop manual DRF 400–450

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

Memory error in control unit transmission.

Transmission locked in neutral (Shut-down).

-

-

-

00/52

7F09D/C

Memory error in control unit transmission.

Transmission locked in neutral (Shut-down).

-

-

-

00/53

7F09D/C

Memory error in control unit transmission.

Transmission locked in neutral (Shut-down).

-

-

-

Workshop manual DRF 400–450

VDRF03.02GB

40

Code 20/60

D Error codes – 2 Transmission

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

Oil pressure sensor (1) has too high oil pressure.

Transmission locked in neutral (Shut-down).

Check the feed pressure to the transmission. Save information about actual pressure when the problem occurred.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code

SPN/FM1

22/00

7F06A/1

Description

Limitation

Action

Oil pressure sensor (2) has too low oil pressure.

Transmission locked in neutral (Shut-down).

Check the feed pressure to the transmission.

41

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

-

-

Save information about actual pressure when the problem occurred. 22/01

7F06A/0

Oil pressure sensor (2) has too high oil pressure.

Transmission locked in neutral (Shut-down).

Check the feed pressure to the transmission. Save information about actual pressure when the problem occurred.

23/00

7F06B/1

Oil pressure sensor (3) has too low oil pressure.

Transmission locked in neutral (Shut-down).

Check the feed pressure to the transmission. Save information about actual pressure when the problem occurred.

23/01

7F06B/0

Oil pressure sensor (3) has too high oil pressure.

Transmission locked in neutral (Shut-down).

Check the feed pressure to the transmission. Save information about actual pressure when the problem occurred.

24/00

7F06C/1

Oil pressure sensor (4) has too low oil pressure.

Transmission locked in neutral (Shut-down).

Check the feed pressure to the transmission. Save information about actual pressure when the problem occurred.

Workshop manual DRF 400–450

VDRF03.02GB

42

D Error codes – 2 Transmission

Code

SPN/FM1

24/01

7F06C/0

Description

Limitation

Action

Oil pressure sensor (4) has too high oil pressure.

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

Save information about actual pressure when the problem occurred. 30/04

30/05

31/00

31/01

34/00

7F090/1

7F090/0

7F093/1

7F093/0

7F0BB/1F

Low battery voltage.

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 control unit.

Check the control unit.

Check the sensor.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

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.

Workshop manual DRF 400–450

VDRF03.02GB

44

D Error codes – 2 Transmission

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 doesn’t 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

Workshop manual DRF 400–450

D Error codes – 2 Transmission

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 warning’s 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.

-

-

-

-

Workshop manual DRF 400–450

VDRF03.02GB

46

D Error codes – 2 Transmission

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.

Control unit indicates the error.

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.

Control unit indicates the error.

Check the 4WD/ 2WD selector.

-

-

Engaged 4WD/2WD selector stuck in engaged mode, or the return signal is incorrect.

Control unit indicates the error.

-

-

Disengaged Low/High selector stuck in engaged mode, or the feedback signal is incorrect.

Control unit indicates the error.

-

-

Engaged Low/High selector stuck in engaged mode, or the return signal is incorrect.

Control unit indicates the error.

-

-

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.

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code 50/00

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 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 locked in gear 1 and 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 identifies the error and use the highest value in its settings.

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 transmission’s 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.

Workshop manual DRF 400–450

Dana full flow D793/H3 B7660

VDRF03.02GB

48

Code 51/01

D Error codes – 2 Transmission

Description

Limitation

Action

Dana

The control unit limits the transmission’s temperature measurement to the highest value in its settings, which results in poor temperature compensation.

Check cabling between control unit and sensor.

The control unit limits the transmission’s temperature measurement to the lowest value in its settings.

Check cabling between control unit and component.

7F011/3

The control unit limits the transmission’s temperature measurement to the highest value in its settings.

Check cabling between control unit and component.

The control unit limits the transmission’s temperature measurement to the highest value in its settings, which results in poor temperature compensation.

Check cabling between control unit and sensor.

The control unit limits the transmission’s temperature measurement to the highest value in its settings, which results in poor temperature 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

Sensor oil temperature (B7660), the value is below the lowest calibrated value.

Sensor oil temperature (B7660), the value is above the highest calibrated value.

Dana Sensor oil temperature (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 Sensor oil temperature (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.

Workshop manual DRF 400–450

Dana D793/J3 - S221

Dana full flow D793/J3 S2210

TRANSM, menu 10

D Error codes – 2 Transmission

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.

The control unit limits the transmission’s temperature measurement to the lowest value in its settings, which results in poor temperature compensation.

Check cabling between control unit and component.

Temperature switch torque converter (S2210), the value is above the highest calibrated value.

The control unit limits the transmission’s temperature measurement to the highest value in its settings, which results in poor temperature 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 locked in gear 1 and 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.

Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings.

Workshop manual DRF 400–450

VDRF03.02GB

50

Code 53/01

D Error codes – 2 Transmission

Description

Limitation

Action

Analogue input signal 3, 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 locked in gear 1 and 2 (Limp-home).

Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 53/04

7F013/11

Analogue input signal 3, the value is below the lowest calibrated value.

The control unit identifies the error and use the lowest value in its settings.

Check cabling between control unit and component. Check the component.

53/05

7F013/F

Analogue input signal 3, the value is above the highest calibrated value.

The control unit identifies the error and use the highest value in its settings.

Check cabling between control unit and component. Check the 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

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code 55/00

Description

Limitation

Action

Analogue input signal 5, short circuited to ground.

Depending on the function that is assigned to the pin:

Check cabling between control unit and component.

51

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

SPN/FM1 7F015/4

Pressure feedback: Transmission locked in gear 1 and 2 (Limp-home).

Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 55/01

7F015/3

Analogue input signal 5, is not connected.

Depending on the function that is assigned to the pin: Pressure feedback: Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component. Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 55/04

7F015/11

Analogue input signal 5, the value is below the lowest calibrated value.

The control unit identifies the error and use the lowest value in its settings.

Check cabling between control unit and component. Check the component.

55/05

7F015/F

Analogue input signal 5, the value is above the highest calibrated value.

The control unit identifies the error and use the highest value in its settings.

Check cabling between control unit and component. Check the component.

Workshop manual DRF 400–450

VDRF03.02GB

52

Code 56/00

D Error codes – 2 Transmission

Description

Limitation

Action

Pressure sensor gear 2/ 4 (B6069), short circuited to ground.

Depending on the function that is assigned to the pin:

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 locked in gear 1 and 2 (Limp-home).

Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 56/01

7F016/3

Pressure sensor gear 2/ 4 (B6069), is not connected.

Depending on the function that is assigned to the pin: Pressure feedback: Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component. Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 56/04

7F016/11

Pressure sensor gear 2/ 4 (B6069), the value is below the lowest calibrated value.

The control unit identifies the error and use the lowest value in its settings.

Check cabling between control unit and component. Check the component.

56/05

7F016/F

Pressure sensor gear 2/ 4 (B6069), the value is above the highest calibrated value.

The control unit identifies the error and use the highest value in its settings.

Check cabling between control unit and component. Check the component.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code 57/00

Description

Limitation

Action

Analogue input signal 7, short circuited to ground.

Depending on the function that is assigned to the pin:

Check cabling between control unit and component.

53

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

SPN/FM1 7F017/4

Pressure feedback: Transmission locked in gear 1 and 2 (Limp-home).

Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 57/01

7F017/3

Analogue input signal 7, is not connected.

Depending on the function that is assigned to the pin: Pressure feedback: Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component. Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 57/04

7F017/11

Analogue input signal 7, the value is below the lowest calibrated value.

The control unit identifies the error and use the lowest value in its settings.

Check cabling between control unit and component. Check the component.

57/05

7F017/F

Analogue input signal 7, the value is above the highest calibrated value.

The control unit identifies the error and use the highest value in its settings.

Check cabling between control unit and component. Check the component.

Workshop manual DRF 400–450

VDRF03.02GB

54

Code 58/00

D Error codes – 2 Transmission

Description

Limitation

Action

Analogue input signal 8, short circuited to ground.

Depending on the function that is assigned to the pin:

Check cabling between control unit and component.

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

SPN/FM1 7F018/4

Pressure feedback: Transmission locked in gear 1 and 2 (Limp-home).

Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 58/01

7F018/3

Analogue input signal 8, is not connected.

Depending on the function that is assigned to the pin: Pressure feedback: Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component. Check the component.

Oil pressure sensor: The control unit locks the transmission in neutral position. Other: The control unit uses the lowest value in its settings. 58/04

7F018/11

Analogue input signal 8, the value is below the lowest calibrated value.

The control unit identifies the error and use the lowest value in its settings.

Check cabling between control unit and component. Check the component.

58/05

7F018/F

Analogue input signal 8, the value is above the highest calibrated value.

The control unit identifies the error and use the highest value in its settings.

Check cabling between control unit and component. Check the component.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

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 signal that is not the engine rpm signal is incorrect, the control unit calculates the missing rpm.

Sensor rpm drum (B752) not connected. Dana full flow Sensor rpm drum (B7520) not connected.

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

Check cable between control unit and sensor. Check the sensor.

Dana D793/C3 B752

TRANSM, menu 6

Dana full flow D793/C3 B7520

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). Control unit indicates the error.

D793/C3 B752

Check cable between control unit and component.

D793/C3 B7520

TRANSM, menu 6

Check component.

Workshop manual DRF 400–450

VDRF03.02GB

56

Code 60/04

D Error codes – 2 Transmission

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 transmission’s settings for the ratio in the control unit. 60/05

7F01A/0

Sensor rpm drum (B7520), pulse count too high.

This message is provided as supplementary information for errors in the transmission.

Check the transmission to find out if, and which, clutch is slipping. Check the transmission’s settings for the ratio in the control unit.

61/00

7F01B/6

Dana Sensor rpm output shaft (B758) short-circuited to ground. Dana full flow Sensor rpm output shaft (B7580) short-circuited to ground.

VDRF03.02GB

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. Check the sensor.

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).

Workshop manual DRF 400–450

D793/E3 B758

Dana full flow D793/E3 B7580

D Error codes – 2 Transmission

Code 61/01

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.

Connections and components

Diagnostic menu

Dana

TRANSM, menu 6

SPN/FM1 7F01B/5

Sensor rpm output shaft (B758) not connected. Dana full flow Sensor rpm output shaft (B7580) not connected.

61/03

57

7F01B/A

Sensor rpm output shaft (B7580), value outside limit values.

Check the sensor.

Dana full flow D793/E3 B7580

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). Control unit indicates the error.

D793/E3 B758

Check cable between control 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

Sensor rpm output shaft (B7580), 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. Check the transmission’s settings for the ratio in the control unit.

61/05

7F01B/0

Sensor rpm output shaft (B7580), pulse count too high.

This message is provided as supplementary information for errors in the transmission.

Check the transmission to find out if, and which, clutch is slipping. Check the transmission’s settings for the ratio in the control unit.

Workshop manual DRF 400–450

VDRF03.02GB

58

Code 62/00

D Error codes – 2 Transmission

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.

7F01C/6

Dana full flow

7F01C/5

Sensor engine speed (B7530), 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 signal that is not the engine rpm signal is incorrect, the control unit calculates 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

Check cable between control unit and sensor.

Dana D793/F3 B758/766

TRANSM, menu 6

Check the sensor. Dana full flow

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).

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 provided as supplementary information for errors in the transmission.

Check the transmission to find out if, and which, clutch is slipping.

D793//F3 B7530

TRANSM, menu 6

Check the transmission’s settings for the ratio in the control unit.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code 62/05

Description

Limitation

Action

Sensor engine speed (B7530), pulse count is too high.

This message is provided as supplementary information for errors in the transmission.

Check the transmission to find 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

Check the transmission’s settings for the ratio 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 component’s position.

63/00

7F01D/6

Dana Sensor rpm turbine (B751) short-circuited to ground. Dana full flow Sensor rpm turbine (B7510) short-circuited to ground.

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. Check the sensor.

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).

Workshop manual DRF 400–450

D793/R2 B751

Dana full flow D793/G3 B7510

VDRF03.02GB

60

Code 63/01

D Error codes – 2 Transmission

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.

Diagnostic menu

Dana

TRANSM, menu 6

SPN/FM1 7F01D/5

Sensor rpm turbine (B751) not connected. Dana full flow Sensor rpm turbine (B7510) not connected.

63/03

Connections and components

7F01D/A

Sensor rpm turbine (B7510), value outside limit values.

Check the sensor.

Dana full flow D793/G3 B7510

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). Control unit indicates the error.

D793/R2 B751

Check cable between control 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 (B7510), 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. Check the transmission’s settings for the ratio in the control unit.

63/05

7F01D/0

Sensor rpm turbine (B7510), pulse count too high.

This message is provided as supplementary information for errors in the transmission.

Check the transmission to find out if, and which, clutch is slipping. Check the transmission’s settings for the ratio in the control unit.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code 70/00

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 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 locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

Dana full flow Servo valve gear forward and reverse (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 locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

Servo valve gear forward and reverse (Y6300), control current over 1400 mA.

Workshop manual DRF 400–450

Dana D793/B1 Y630, C1 Y630

TRANSM, menu 9

Dana full flow D793/B1 Y6300, D793/ C1 - Y6300

VDRF03.02GB

62

Code 70/03

D Error codes – 2 Transmission

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

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 Servo valve gear forward and reverse (Y6300), control current outside the approved interval. Incorrect impedance. 70/09

Connections and components

7F020/5

Servo valve gear forward and reverse (Y6300), not connected.

D793/B1 Y630, D793/C1 - Y630

Check the solenoid valve. Transmission locked in neutral (Shut-down).

Transmission locked in gear 1 and 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

Check the solenoid valve. 71/00

7F021/4

Dana Solenoid valve VFS 2/4 (Y6069), short-circuited to each other, signal cable short-circuited to voltage, or plus-cable short-circuited to frame ground.

VDRF03.02GB

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

D793/D1 Y6069, D793/ E1 - Y6069

Check the solenoid valve.

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

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code 71/01

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

7F021/3

Check the solenoid valve.

Dana full flow Solenoid valve gear selection 1/3 (Y6067), open circuit or shortcircuited voltage. 7F021/6

Dana Solenoid valve VFS 2/4 (Y6069), control current higher than 1400 mA.

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

Solenoid valve gear selection 1/3 (Y6067), control current higher than 1400 mA. 7F021/8

Dana Solenoid valve VFS 2/4 (Y6069), control current 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

Solenoid valve VFS 2/4 (Y6069) open circuit or short-circuited voltage.

71/02

63

Dana D793/D1 Y6069, D793/ E1 - Y6069 Dana full flow D793/D1 Y6067, D793/ E1 - Y6067

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

Dana D793/D1 Y6069, D793/ E1 - Y6069

TRANSM, menu 9

Check the solenoid valve.

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 locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component.

D793/D1 Y6067, D793/ E1 - Y6067

TRANSM, menu 9

Check the solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

64

Code 72/00

D Error codes – 2 Transmission

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

7F022/4

Dana

TRANSM, menu 8

7F022/3

Check the solenoid valve.

Dana full flow

Solenoid valve gear selection 2/4 (Y6069), short-circuited to each other, signal cable short-circuited to voltage, or plus-cable shortcircuited to frame ground.

D793/F1 Y6069, D793/ G1 - Y6069

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

Dana full flow Solenoid valve gear selection 2/4 (Y6069), 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 locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

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 short-circuited to each other, signal cable short-circuited to voltage, or plus-cable shortcircuited to frame ground.

72/01

Connections and components

Workshop manual DRF 400–450

Dana D793/F1 Y631, D793/G1 - Y631

Dana full flow D793/F1 Y6069, D793/ G1 - Y6069

TRANSM, menu 9

-

D Error codes – 2 Transmission

Code 72/03

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

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

Check the solenoid valve.

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

Solenoid valve gear selection 2/4 (Y6069), not connected.

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component.

Dana full flow

-

-

D793/F1 Y6069, D793/ G1 - Y6069

Check the component. 73/00

7F023/4

Dana Solenoid valve VFS 1/3 (Y6067), cables shortcircuited to each other, signal cable shortcircuited to voltage, or plus-cable shortcircuited to frame ground.

73/00

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

Dana D793/H1 Y6067, D793/ J1 - Y6067

TRANSM, menu 8

Check the solenoid valve.

Dana full flow

Dana full flow

Analogue output signal 3, cables short-circuited to each other, signal cable short-circuited to voltage or plus-cable short-circuited to frame ground.

-

Workshop manual DRF 400–450

VDRF03.02GB

66

Code 73/01

D Error codes – 2 Transmission

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

7F023/3

Check the solenoid valve.

Dana full flow Analogue output signal 3, open circuit or shortcircuited voltage. 7F023/6

Dana Solenoid valve VFS 1/3 (Y6067), control current higher than 1400 mA.

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

Analogue output signal 3, control current over 1400 mA. 7F023/8

Dana Solenoid valve VFS 1/3 (Y6067), control current 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

Solenoid valve VFS 1/3 (Y6067) open circuit or short-circuited voltage.

73/02

Connections and components

Dana D793/H1 Y6067, J1 Y6067 Dana full flow -

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

Dana D793/H1 Y6067, J1 Y6067

TRANSM, menu 9

Check the solenoid valve.

Dana full flow

Dana full flow

Analogue output signal 3, control current outside the approved interval (incorrect impedance).

-

Analogue output signal 3, not connected.

TRANSM, menu 9

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component.

-

-

-

-

Check the solenoid valve. 74/00

7F024/4

Analogue output signal 4, short circuited to ground.

Control unit indicates the error.

Check cabling between control unit and component. Check the component.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code

SPN/FM1

74/01

7F024/3

Description

Limitation

Action

Analogue output signal 4 not connected or short-circuited voltage.

Control unit indicates the error.

Check cabling between control unit and component.

67

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

-

-

-

-

Check the component. 75/00

7F025/4

Analogue output signal 5, short circuited to ground.

Control unit indicates the error.

Check cabling between control unit and component. Check the component.

75/01

7F025/3

Analogue output signal 5 not connected or short-circuited voltage.

Control unit indicates the error.

Check cabling between control unit and component. Check the component.

76/00

7F026/4

Analogue output signal 6, short circuited to ground.

Control unit indicates the error.

Check cabling between control unit and component. Check the component.

76/01

7F026/3

Analogue output signal 6, not connected or short-circuited voltage.

Control unit indicates the error.

Check cabling between control unit and component. Check the component.

76/02

7F026/6

Analogue output signal 6, control current over 1400 mA.

Control unit indicates the error.

Check cabling between control unit and component. Check the component.

Workshop manual DRF 400–450

VDRF03.02GB

68

D Error codes – 2 Transmission

Code

SPN/FM1

76/03

7F026/8

Description

Limitation

Action

Analogue output signal 6, output signal outside the approved interval (incorrect impedance).

Control unit indicates the error.

Check cabling between control unit and component.

Connections and components

Diagnostic menu

-

-

-

-

Check the component. 76/09

7F026/5

Analogue output signal 3, not connected.

Control unit indicates the error.

Check cabling between control unit and component. Check the component.

77/02

7F02F/1F

All gear packs disengaged.

Transmission locked in neutral (Shut-down).

-

-

-

80/00

7F027/4

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component.

Dana

Dana

D793/K1 Y6066

TRANSM, menu 7

Solenoid valve RSP Drive (Y6066), cable short-circuited to frame ground.

Check the solenoid valve.

Dana full flow Solenoid valve drive forward (Y6066F), cable short-circuited to frame 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 locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component. Check the solenoid valve.

Solenoid valve drive forward (Y6066F), cable is not connected or shortcircuited to voltage.

VDRF03.02GB

Dana full flow

Workshop manual DRF 400–450

Dana

Dana

D793/K1 Y6066

TRANSM, menu 7

Dana full flow D793/K1 Y6066F

D Error codes – 2 Transmission

Code 80/09

Description

Limitation

Action

Solenoid valve drive forward (Y6066F), not connected.

Transmission locked in gear 1 and 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

Check the solenoid valve. 81/00

7F028/4

Dana Solenoid valve VFS 2/4 (Y6074), cable shortcircuited to frame ground.

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

Dana full flow Solenoid valve drive reverse (Y6066R), cable short-circuited to frame ground. 81/01

7F027/3

Dana Solenoid valve VFS 2/4 (Y6074), cable is not connected or shortcircuited to voltage.

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

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 locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and component.

D793/E2 Y6066R

TRANSM, menu 7

Check the solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

70

Code 82/00

D Error codes – 2 Transmission

Description

Limitation

Action

Dana

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

7F029/4

Check the solenoid valve.

Dana full flow Solenoid valve gear selection 1/3 (Y6075), cable short-circuited to frame ground. 7F029/3

Dana Solenoid valve VFS 1/3 (Y6075), cable is not connected or shortcircuited to voltage.

Dana

TRANSM, menu 7

Transmission locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve. Check the solenoid valve.

Solenoid valve gear selection 1/3 (Y6075), cable short-circuited to voltage. 7F029/5

Solenoid valve gear selection 1/3 (Y6075), not connected.

D793/F2 Y6075

Dana full flow D793/F2 Y6075

Dana full flow

82/09

Diagnostic menu

SPN/FM1

Solenoid valve VFS 1/3 (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 locked in gear 1 and 2 (Limp-home).

Check cabling between control unit and solenoid valve.

D793/F2 Y6075

TRANSM, menu 7

Dana

Dana

D793/K2 Y6066

TRANSM, menu 7

Check the solenoid valve. 83/00

7F02A/3

Dana Solenoid valve RSP Drive (Y6066), cable short-circuited to frame ground. Dana full flow

Transmission locked in neutral (Shut-down).

Check cabling between control unit and component. Check the component.

Solenoid valve gear selection 2/4 (Y6074), cable short-circuited to frame ground.

VDRF03.02GB

Workshop manual DRF 400–450

Dana full flow D793/K2 Y6074

D Error codes – 2 Transmission

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 not connected or shortcircuited to voltage. Dana full flow Solenoid valve gear selection 2/4 (Y6074), cable short-circuited to voltage.

Transmission locked in neutral (Shut-down).

Check the component.

Dana full flow D793/K2 Y6074

90/01

7F0F0/1

Software error Control unit, transmission (D793).

-

-

-

-

90/02

7F0F0/2

Software error Control unit, transmission (D793).

-

-

-

-

90/03

7F0F0/3

Software error Control unit, transmission (D793).

-

-

-

-

90/04

7F0F0/4

Software error Control unit, transmission (D793).

-

-

-

-

90/05

7F0F0/5

Software error Control unit, transmission (D793).

-

-

-

-

90/06

7F0F0/6

Software error Control unit, transmission (D793).

-

-

-

-

90/07

7F0F0/7

Software error Control unit, transmission (D793).

-

-

-

-

90/08

7F0F0/8

Software error Control unit, transmission (D793).

-

-

-

-

90/09

7F0F0/9

Software error Control unit, transmission (D793).

-

-

-

-

90/11

7F0F0/B

Software error Control unit, transmission (D793).

-

-

-

-

Workshop manual DRF 400–450

VDRF03.02GB

72

D Error codes – 2 Transmission

Description

Limitation

Action

Connections and components

Diagnostic menu

Code

SPN/FM1

90/12

7F0F0/C

Software error Control unit, transmission (D793).

-

-

-

-

90/13

7F0F0/D

Software error Control unit, transmission (D793).

-

-

-

-

90/14

7F0F0/E

Software error Control unit, transmission (D793).

-

-

-

-

90/15

7F0F0/F

Software error Control unit, transmission (D793).

-

-

-

-

90/16

7F0F0/10

Software error Control unit, transmission (D793).

-

-

-

-

90/17

7F0F0/11

Software error Control unit, transmission (D793).

-

-

-

-

90/18

7F0F0/12

Software error Control unit, transmission (D793).

-

-

-

-

90/19

7F0F0/13

Software error Control 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

Software error Control unit, transmission (D793).

-

-

-

-

91/02

7F0F1/2

Software error Control unit, transmission (D793).

-

-

-

-

91/03

7F0F1/3

Software error Control unit, transmission (D793).

-

-

-

-

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

73

Description

Limitation

Action

Connections and components

Diagnostic menu

Code

SPN/FM1

91/10

7F0F1/6

Software error Control unit, transmission (D793).

-

-

-

-

91/11

7F0F1/7

Software error Control unit, transmission (D793).

-

-

-

-

91/12

7F0F1/8

Software error Control unit, transmission (D793).

-

-

-

-

91/50

7F0F7/A

Software error Control unit, transmission (D793).

-

-

-

-

91/51

7F0F7/B

Software error Control unit, transmission (D793).

-

-

-

-

91/52

7F0F7/C

Software error Control unit, transmission (D793).

-

-

-

-

91/53

7F0F7/D

Software error Control unit, transmission (D793).

-

-

-

-

91/54

7F0F7/E

Software error Control unit, transmission (D793).

-

-

-

-

91/55

7F0F7/F

Software error Control unit, transmission (D793).

-

-

-

-

91/57

7F0F7/11

Software error Control unit, transmission (D793).

-

-

-

-

91/58

7F0F7/12

Software error Control unit, transmission (D793).

-

-

-

-

91/59

7F0F7/13

Software error Control unit, transmission (D793).

-

-

-

-

91/60

7F0F7/14

Software error Control unit, transmission (D793).

-

-

-

-

Workshop manual DRF 400–450

VDRF03.02GB

74

D Error codes – 2 Transmission

Description

Limitation

Action

Connections and components

Diagnostic menu

Code

SPN/FM1

91/61

7F0F7/15

Software error Control unit, transmission (D793).

-

-

-

-

91/70

7F0F7/1E

Software error Control unit, transmission (D793).

-

-

-

-

92/00

7F0F2/0

Software error Control 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

Digital input signal "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

Workshop manual DRF 400–450

D Error codes – 2 Transmission

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.

-

-

Workshop manual DRF 400–450

VDRF03.02GB

76

D Error codes – 2 Transmission

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

Software error Control unit, transmission (D793).

-

-

-

-

92/51

7F0F8/2

Software error Control unit, transmission (D793).

-

-

-

-

92/52

7F0F8/3

Software error Control 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

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.

-

-

93/02

7F0F3/2

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.

-

-

93/03

7F0F3/3

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.

-

-

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Description

Limitation

Action

77

Connections and components

Diagnostic menu

Code

SPN/FM1

93/04

7F0F3/4

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.

-

-

93/05

7F0F3/5

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.

-

-

93/09

7F0F3/9

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.

-

-

93/10

7F0F3/A

Initiation of statistical data in flash memory, caused by firmware update or a memory conflict.

Control unit indicates the error.

Switch off the machine and the main electrical power.

-

-

93/11

7F0F3/B

Initiation of stored incorrect data in flash memory, caused by firmware update or a memory conflict.

Control unit indicates the error.

Switch off the machine and the main electrical power.

-

-

94/00

7F0F4/0

Failed initialisation of the necessary control unit data in flash memory, caused by a memory conflict.

Transmission locked in neutral (Shut-down).

Note the time and contact Cargotec support.

-

-

94/01

7F0F4/1

Failed initialisation of the necessary control unit data in flash memory, caused by a memory conflict.

Transmission locked in neutral (Shut-down).

Note the time and contact Cargotec support.

-

-

94/02

7F0F4/2

Failed initialisation of the necessary control unit data in flash memory, caused by a memory conflict.

Transmission locked in neutral (Shut-down).

Note the time and contact Cargotec support.

-

-

Workshop manual DRF 400–450

VDRF03.02GB

78

D Error codes – 2 Transmission

Description

Limitation

Action

Connections and components

Diagnostic menu

Code

SPN/FM1

94/03

7F0F4/3

Failed initialisation of the necessary control unit data in flash memory, caused by a memory conflict.

Transmission locked in neutral (Shut-down).

Note the time and contact Cargotec support.

-

-

94/04

7F0F4/4

Failed initialisation of the necessary control unit data in flash memory, caused by a memory conflict.

Transmission locked in neutral (Shut-down).

Note the time and contact Cargotec support.

-

-

94/05

7F0F4/5

Failed initialisation of the necessary control unit data in flash memory, caused by a memory conflict.

Transmission locked in neutral (Shut-down).

Note the time and contact Cargotec support.

-

-

94/09

7F0F4/9

Failed initialisation of the necessary control unit data in flash memory, caused by a memory conflict.

Transmission locked in neutral (Shut-down).

Note the time and contact Cargotec support.

-

-

95/00

7F0F5/0

-

-

-

-

-

95/70

7F0F5/14

Software error Control 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

Software error Control unit, transmission (D793).

-

-

-

-

95/73

7F0F5/17

Software error Control unit, transmission (D793).

-

-

-

-

7F0F6/0

Incorrect software in control unit transmission.

-

-

-

-

7F0F6/1

Software error Control unit, transmission (D793).

-

-

-

-

95/71

99/90

99/91

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

79

Description

Limitation

Action

Connections and components

Diagnostic menu

Code

SPN/FM1

99/92

7F0F6/2

Software error Control unit, transmission (D793).

-

-

-

-

99/93

7F0F6/3

Software error Control 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

Software error Control 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.

-

-

-

Workshop manual DRF 400–450

VDRF03.02GB

80

D Error codes – 2 Transmission

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 driver’s 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

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code

SPN/FM1

E.1.06

7F0FA 7F0FD/6

Description

Limitation

Action

Calibration of drive mode pressure, during calibration the turbine speed signal does not reach down to the lowest value.

The control unit identifies the error 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

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.

E.1.10

7F0FA 7F0FD/A

Calibration of drive mode pressure, transmission error during calibration.

The calibration is stopped.

Determine the reason why calibration was stopped.

-

-

E.1.11 -13

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.

Workshop manual DRF 400–450

VDRF03.02GB

82

D Error codes – 2 Transmission

Code

SPN/FM1

E.1.14

7F0FA 7F0FD/E

E.1.15

7F0FA 7F0FD

Description

Limitation

Action

Calibration of drive mode pressure, during calibration the turbine speed does not decrease.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks.

Calibration of drive mode pressure, unexpected algorithm response.

The calibration is stopped.

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

Check the signal from the turbine speed sensor. Download the correct parameters and repeat calibration. Make sure that the machine does not move. Check engine speed response.

E.1.16

7F0FA 7F0FD/10

Calibration of drive mode pressure, the turbine speed is too low to start calibration.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor.

E.1.17 -24

7F0FA 7F0FD

Calibration of drive mode pressure, unexpected algorithm response.

The calibration is stopped.

Download the correct parameters and resume calibration. Check if the machine starts to move. Check engine speed response.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code

SPN/FM1

E.1.25

7F0FA 7F0FD/19

Description

Limitation

Action

Calibration of drive mode pressure, the starting point of engagement is too early during calibration. Too much traction.

The control unit identifies the error 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

Calibration of drive mode pressure, engagement starting point cannot be identified.

The control unit identifies the error and the calibration is stopped.

Calibrating at higher temperatures (90100 C). Check the speed sensors (error code 42/ 04 or 42/05). Check the servo valves.

E.1.27

7F0FA 7F0FD

Calibration of drive mode pressure, unexpected algorithm response.

The calibration is stopped.

Download the correct parameters and resume calibration. Check if the machine starts to move. Check engine speed response.

E.1.28

7F0FA 7F0FD/1C

Calibration of drive mode pressure, turbine speed does not reach a value of 0 rpm during the closing phase of calibration.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor.

Workshop manual DRF 400–450

VDRF03.02GB

84

D Error codes – 2 Transmission

Code

SPN/FM1

E.1.29

7F0FA 7F0FD/1D

Description

Limitation

Action

Calibration of drive mode pressure, turbine speed does not reach the correct value during the release phase of the engagement’s starting point during calibration.

The control unit identifies the error and the calibration is stopped.

Calibrating at higher temperatures (90100 C).

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 correct parameters and repeat calibration. Make sure that the machine does not move. Check engine speed response.

E.2.06

7F0FA 7F0FD/6

Calibration optimisation of filling time, during calibration the turbine speed signal does not reach down to the lowest value.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor. Check the stall speed in order to detect slipping clutch.

E.2.07 -09

7F0FA 7F0FD

Calibration optimisation of filling time, 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

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Description

Limitation

Action

85

Connections and components

Diagnostic menu

Code

SPN/FM1

E.2.10

7F0FA 7F0FD/A

Calibration optimisation of filling time, transmission error during calibration.

The calibration is stopped.

Determine the reason why calibration was stopped.

-

-

E.2.11 -13

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. E.2.14

E.2.15

7F0FA 7F0FD/E

7F0FA 7F0FD

Calibration optimisation of filling time, during calibration the turbine speed does not decrease.

The control unit identifies the error and the calibration is stopped.

Calibration optimisation of filling time, unexpected algorithm response.

The calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor. Download the correct parameters and repeat calibration. Make sure that the machine does not move. Check engine speed response.

E.2.16

7F0FA 7F0FD/10

Calibration optimisation of filling time, the turbine speed is too low to start calibration.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor.

Workshop manual DRF 400–450

VDRF03.02GB

86

D Error codes – 2 Transmission

Code

SPN/FM1

E.2.17 -24

7F0FA 7F0FD

Description

Limitation

Action

Calibration optimisation of filling time, unexpected algorithm response.

The calibration is stopped.

Download the correct parameters and resume calibration.

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

Check if the machine starts to move. Check engine speed response. E.2.25

7F0FA 7F0FD/19

Calibration optimisation of filling time, the starting point of engagement is too early during calibration. Too much traction.

The control unit identifies the error and the calibration is stopped.

Calibrating at higher temperatures (90100 C). Check the speed sensors (error code 42/ 04 or 42/05). Check the servo valves.

E.2.26

7F0FA 7F0FD/1A

Calibration optimisation of filling time, engagement starting point cannot be identified.

The control unit identifies the error and the calibration is stopped.

Calibrating at higher temperatures (90100 C). Check the speed sensors (error code 42/ 04 or 42/05). Check the servo valves.

E.2.27

7F0FA 7F0FD

Calibration optimisation of filling time, unexpected algorithm response.

The calibration is stopped.

Download the correct parameters and resume calibration. Check if the machine starts to move. Check engine speed response.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code

SPN/FM1

E.2.28

7F0FA 7F0FD/1C

E.229

7F0FA 7F0FD/1D

Description

Limitation

Action

Calibration optimisation of filling time, turbine speed does not reach a value of 0 rpm during the closing phase of calibration.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks.

Calibration optimisation of filling time, turbine speed does not reach the correct value during the release phase of the engagement’s starting point during calibration.

The control unit identifies the error and the calibration is stopped.

87

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

Check the signal from the turbine speed sensor. Calibrating at higher temperatures (90100 C). Check the speed sensors (error code 42/ 04 or 42/05). Check the servo valves.

E.3.01 -05

7F0FA 7F0FD

Calibration optimisation of filling time, 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.

E.3.06

7F0FA 7F0FD/6

Calibration optimisation of filling time, during calibration the turbine speed signal does not reach down to the lowest value.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor. Check the stall speed in order to detect slipping clutch.

Workshop manual DRF 400–450

VDRF03.02GB

88

D Error codes – 2 Transmission

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 correct parameters and repeat calibration.

Connections and components

Diagnostic menu

-

-

Make sure that the machine does not move. Check engine speed response. E.3.10

7F0FA 7F0FD/A

Calibration of control current for pressure, transmission error during calibration.

The calibration is stopped.

Determine the reason why calibration was stopped.

-

-

E.3.11 -13

7F0FA 7F0FD

Calibration of control current for 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. E.3.14

E.3.15

7F0FA 7F0FD/E

7F0FA 7F0FD

Calibration of control current for pressure, during calibration the turbine speed does not decrease.

The control unit identifies the error and the calibration is stopped.

Calibration of control current for pressure, unexpected algorithm response.

The calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor. Download the correct parameters and repeat calibration. Make sure that the machine does not move. Check engine speed response.

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 2 Transmission

Code

SPN/FM1

E.3.16

7F0FA 7F0FD/10

Description

Limitation

Action

Calibration of control current for pressure, the turbine speed is too low to start calibration.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks.

89

Connections and components

Diagnostic menu

-

-

-

-

-

-

-

-

Check the signal from the turbine speed sensor. E.3.17 -24

7F0FA 7F0FD

Calibration of control current for pressure, unexpected algorithm response.

The calibration is stopped.

Download the correct parameters and resume calibration. Check if the machine starts to move. Check engine speed response.

E.3.25

7F0FA 7F0FD/19

Calibration of control current for pressure, the starting point of engagement is too early during calibration. Too much traction.

The control unit identifies the error and the calibration is stopped.

Calibrating at higher temperatures (90100 C). Check the speed sensors (error code 42/ 04 or 42/05). Check the servo valves.

E.3.26

7F0FA 7F0FD/1A

Calibration of control current for pressure, engagement starting point cannot be identified.

The control unit identifies the error and the calibration is stopped.

Calibrating at higher temperatures (90100 C). Check the speed sensors (error code 42/ 04 or 42/05). Check the servo valves.

Workshop manual DRF 400–450

VDRF03.02GB

90

D Error codes – 2 Transmission

Code

SPN/FM1

E.3.27

7F0FA 7F0FD

Description

Limitation

Action

Calibration of control current for pressure, unexpected algorithm response.

The calibration is stopped.

Download the correct parameters and resume calibration.

Connections and components

Diagnostic menu

-

-

-

-

-

-

Check if the machine starts to move. Check engine speed response. E.3.28

E.3.29

7F0FA 7F0FD/1C

7F0FA 7F0FD/1D

Calibration of control current for pressure, turbine speed does not reach a value of 0 rpm during the closing phase of calibration.

The control unit identifies the error and the calibration is stopped.

Calibration of control current for pressure, turbine speed does not reach the correct value during the release phase of the engagement’s starting point during calibration.

The control unit identifies the error and the calibration is stopped.

Measure the clutch pressure in order to detect leaks. Check the signal from the turbine speed sensor. Calibrating at higher temperatures (90100 C). Check the speed sensors (error code 42/ 04 or 42/05). Check the servo valves.

VDRF03.02GB

Workshop manual DRF 400–450

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

1

Communication error with attachment control unit (D791-1).

Attachment functions not working.

Use diagnostic menu to find incorrect segment.

D791-1

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

2

Communication error with Control unit, attachment option (D791-2).

Levelling, tilt, overheight extension not working.

Use diagnostic menu to find incorrect segment.

D791-2

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

3

Communication error with Control unit, attachment left jack pair (D791-3).

Left side of bottom lift not working.

Use diagnostic menu to find incorrect segment.

D791-3

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

4

Communication error with Control unit, attachment right jack pair (D791-4).

Right side of bottom lift not working.

Use diagnostic menu to find incorrect segment.

D791-4

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

5

Communication error with Control unit, frame rear (D797-R).

Lighting rear, hydraulic oil cooling, overload system, extension not working.

Use diagnostic menu to find incorrect segment.

D797-R

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

6

Communication error with Control unit, frame front (D797-F).

Front lighting, lift, extension, brake lights, brake cooling not working.

Use diagnostic menu to find incorrect segment.

D797-F

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

7

Communication error with Control unit, frame option (D797O).

Sliding cab, support jacks, joystick control miniwheel, cab lift and cab tilt not working.

Use diagnostic menu to find incorrect segment.

D797-O

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

8

Communication error with KID control unit (D795)

Controls in steering wheel panel and display not working.

Use diagnostic menu to find incorrect segment.

D795

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

Workshop manual DRF 400–450

VDRF03.02GB

92

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

9

Communication error with Control unit, cab option (D790-3).

Mini-wheel or joystick control not working

Use diagnostic menu to find incorrect segment.

D790-3

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

11

Wiring fault CAN bus segment 1.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

12

Wiring fault CAN bus segment 2.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

13

Wiring fault CAN bus segment 3.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

14

Wiring fault CAN bus segment 4.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

15

Wiring fault CAN bus segment 5.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

16

Wiring fault CAN bus segment 6.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

17

Wiring fault CAN bus segment 7.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

18

Wiring fault CAN bus segment 8.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

93

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

9

Communication error with Control unit, cab option (D790-3).

Mini-wheel or joystick control not working

Use diagnostic menu to find incorrect segment.

D790-3

CAN/ POWER, menu 2

11.6.2 Redundant CAN-bus

11

Wiring fault CAN bus segment 1.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

12

Wiring fault CAN bus segment 2.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

13

Wiring fault CAN bus segment 3.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

14

Wiring fault CAN bus segment 4.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

15

Wiring fault CAN bus segment 5.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

16

Wiring fault CAN bus segment 6.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

17

Wiring fault CAN bus segment 7.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

CAN/ POWER, menu 1 and 21

11.6.2 Redundant CAN-bus

18

Wiring fault CAN bus segment 8.

No limitation.

Use diagnostic menu to find incorrect segment.

Varies depending on machine configuration.

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

Workshop manual DRF 400–450

VDRF03.02GB

94

D Error codes – 8 Control system

Code

21

22

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Communication error with transmission control unit (D793).

Gear selection not working.

Use diagnostic menu to 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.

Use diagnostic menu to 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

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

VDRF03.02GB

Workshop manual DRF 400–450

D Error codes – 8 Control system

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).

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

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.

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

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.

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

D790-1/K2:4 – M650-2/53

CAB, menu 3

9.5.7 Wiper motor rear

The transistor has been triggered due to 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

Check the component.

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

D791-1/K8:13 – S107/1

Check the switch.

Repeat software download.

40 41

42

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

Workshop manual DRF 400–450

VDRF03.02GB

96

D Error codes – 8 Control system

Code

43

44

45

46

47

48

49

50

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to 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 been triggered due to 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 been triggered due to short circuit in the circuit for Wiper motor, front (M650-1).

Windscreen wiper front not working.

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

D790-1/K2:1 – M650-1/53

CAB, menu 2

9.5.1 Wiper front

The transistor has been triggered due to 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 been triggered due to 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 been triggered due to 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 been triggered due to 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 been triggered due to 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 cabling between the control unit and the component with diagnostic menu.

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

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

51

53

54

55

56

57

60

97

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit in the circuit for Damper motor (Y672).

Air distribution in cab cannot be adjusted.

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

D790-1/K4:4 – Y672/6

CLIMATE, menu 8

9.4.14 Air distributor

The transistor has been triggered due to 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 been triggered due to 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 been triggered due to 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 been triggered due to short circuit or open circuit in the circuit for LED indication for tilt lock in control lever (S815).

Indication for tilt lock in control lever not illuminated.

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

D790-1/K7:8 – S815/5

-

7.1.1 Control lever

The transistor has been triggered due to short circuit or open circuit in the circuit for LED indication for levelling lock in control lever (S815).

Indication for levelling lock in control lever not illuminated.

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

D790-1/K7:9 – S815/7

-

7.1.1 Control lever

The transistor has been triggered due to short circuit or open circuit in the circuit for Relay seat heater (K383).

Seat heating not working.

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

D790-1/K10:7 – K383/86

CAB, menu 8

9.3.3 Heating coils

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

Check cable harness to background lighting.

Check the switch.

Check the switch.

Check the component.

Workshop manual DRF 400–450

VDRF03.02GB

98

D Error codes – 8 Control system

Code

61

62

63

64

65

66

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Relay extra working lights boom (K304).

Extra working lights boom not working.

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

D790-1/K10:8 – K304/86

LIGHTS, menu 3

9.6.10 Working lights, boom

The transistor has been triggered due to short circuit or open 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 been triggered due to short circuit or open circuit in the circuit for Relay ignition voltage (K315-1).

No ignition voltage to the machine’s Control units.

D790-1/ K10:10 – K315-1/86

CAN/ POWER, menu 4

11.5.1.3 Ignition voltage (15)

The transistor has been triggered due to short circuit or open circuit in circuit for relay for emergency stop switch voltage (K3009-1).

No emergency stop switch voltage to the machine’s control units.

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

D790-1/ K10:11 – K3009-1/86

CAN/ POWER, menu 5

11.5.1.4 Emergency stop switch voltage

The transistor has been triggered due to short circuit or open circuit in circuit for relay for emergency stop switch voltage (K3009-2).

No emergency stop switch voltage to the machine’s control units.

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

D790-1/ K10:11 – K3009-1/86

CAN/ POWER, menu 5

11.5.1.4 Emergency stop switch voltage

The transistor has been triggered due to short circuit in the circuit for Washer motor, windscreen (M651-1).

Windscreen washer not working.

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

D790-1/ K10:13 – M651-1

CAB, menu 1

9.5.4 Washer motor and reservoir

VDRF03.02GB

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

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

Check the component.

Check the component.

Check the component.

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

67

68

69

71

74

75

99

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Wiper motor, roof (M650-3).

Wiper roof not working.

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

D790-1/ K10:14 – M650-3/53

CAB, menu 4

9.5.6 Wiper motor roof

The transistor has been triggered due to short circuit or open 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 been triggered due to short circuit or open circuit in the circuit for Relay ignition voltage drivetrain (K315-2).

No voltage feed to engine and transmission.

D790-1/ K10:16 – K315-2/86

CAN/ POWER, menu 4

11.5.1.3 Ignition voltage (15)

The transistor has been triggered due to 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 been triggered due to short circuit in the circuit for horn (H850) or Relay loud horn (K3016)

Horn/loud horn not working.

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

D790-1/ K11:11 – H850/1, K3016/86

CAB, menu 5

9.7.1 Horn

Relay ignition voltage (K315-1) has jammed in position on.

The cab control unit (D790-1) is still energised and is thereby active.

-

CAN/ POWER, menu 4

11.5.1.3 Ignition voltage

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

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

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

Workshop manual DRF 400–450

VDRF03.02GB

100

D Error codes – 8 Control system

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

81

Faulty signal from Actuating motor (Y672). Signal voltage under 0.2 V or over 4.8 V.

Air distribution cannot be changed.

Check cabling between the control unit and the component with diagnostic menu. 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. Signal voltage under 0.2 V or over 4.8 V.

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

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.

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

D790-1/K9:8 – R825-1/P2

STEERING, menu 1

5.1.2 Miniwheel

Faulty signal from Mini-wheel (R825-2). Signal voltage under 0.2 V or over 4.8 V.

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

Air conditioning not working.

Faulty signal from outside temperature sensor (B774). Temperature signal over 105 °C.

Air conditioning not working.

Faulty signal from outlet fan temperature sensor (B775-2) Sensor indicates temperature under 43 °C or over 105 °C.

Air conditioning not working.

Faulty signal from refrigerant temperature sensor (B775-3) Sensor indicates temperature under -43 °C or over 105 °C.

Air conditioning not working.

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

Workshop manual DRF 400–450

VDRF03.02GB

102

Code

101

102

103

104

105

106

107

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Redundant voltage feed left to Control unit, frame front (D797-F) does not reach destination.

-

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

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

11.5.1.2 Redundant voltage feed of 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

11.5.1.3 Ignition voltage (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.

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

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 been triggered due to short circuit in the circuit for Cooling fan, brake fluid (M674).

Cooling fan brake oil not working.

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

D797-F/K1:14 – M674/1

HYD, menu 2

4.8.8 Cooling fan

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 control unit. Check cabling between the control unit and the component with diagnostic menu. Check the control unit.

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

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

Check the sensor.

Check the motor. Check bulb. Check the lamp holder. Check cabling between the control unit and the component with diagnostic menu.

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

108

110

111

112

113

114

103

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to 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 been triggered due to short circuit in the circuit for Solenoid valve, boom down (Y6004).

Lower not working.

D797-F/K1:3 – Y6004/1

BOOM, menu 5

7.2.5 Control valve lift, lower and extension

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, boom out (Y6006).

Extension out not working.

D797-F/K1:4 – Y6006/1

BOOM, menu 7

7.3.5 Control valve lift, lower and extension

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, boom in (Y6007).

Extension in not working.

D797-F/K1:5 – Y6007/1

BOOM, menu 6

7.3.5 Control valve lift, lower and extension

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

Check the lamp holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

104

Code

115

116

117

118

119

120

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, blocking lift, left (Y6002).

Lifting/lowering not working.

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

D797-F/K1:30 – Y6002/1

BOOM, menu 2

7.2.7 Valve block lift cylinder

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, blocking lift, right (Y6001).

Lifting/lowering not working.

D797-F/K1:31 – Y6001/1

BOOM, menu 2

7.2.7 Valve block lift cylinder

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check bulb. Check the lamp holder. Check cabling between the control unit and the component with diagnostic menu.

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

121

122

123

124

133

105

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Lamp, direction indicator, right front (H423).

Direction indicator front right not working.

Check bulb.

D797-F/K1:10 – H423/1

LIGHTS, menu 8

9.6.6 Direction indicators

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for Lamp, position light, right front (H417-1).

Position light front right not working.

Check bulb.

D797-F/K1:29 – H417-1/1

LIGHTS, menu 5

9.6.2 Running lights

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.

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

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.

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

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

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

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

4.3.8 NO (normally open) switch, brake lights

Check the sensor.

4.3.7 NC (normally closed) switch, brake pressure

Check the sensor.

Workshop manual DRF 400–450

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

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Faulty signal from Sensor hydraulic pressure lift cylinder left (B768-L2). 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.

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

D797-F/K1:22 – B768-L2/3

OP, menu 3 [V]

7.2.9 Sensor hydraulic pressure lift cylinder

Faulty signal from Sensor hydraulic pressure lift cylinder right (B768-R1). 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.

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

Faulty signal from Sensor hydraulic pressure lift cylinder right (B768-R2). 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.

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

Faulty signal from Solenoid valve, boom up (Y6005). Return current does not match control current.

Lift not working.

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

Faulty signal from Solenoid valve, boom down (Y6004). Return current does not match control current.

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 valve lift, lower and extension

D797-F/K1:17 – Y6004/2

BOOM, menu 5

7.2.5 Control valve lift, lower and extension

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

139

140

145

146

147

107

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Faulty signal from Solenoid valve, boom out (Y6006). Return current does not match control current.

Extension out not working.

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

D797-F/K1:18 – Y6006/2

BOOM, menu 7

7.3.5 Control valve lift, lower and extension

Faulty signal from Solenoid valve, boom in (Y6007). Return current does not match control current.

Extension in not working.

D797-F/K1:19 – Y6007/2

BOOM, menu 6

7.3.5 Control valve lift, lower and extension

Faulty signal from Sensor, boom angle (B771). Logical error, the signal does not change when lifting or lowering is activated.

Overload system not working. All lift functions operate at reduced speed. Error code 150 is activated.

Check sensor arm mounting.

-

OP, menu 4

8.2.1.5 Sensor, boom angle

Faulty signal from Sensor, boom length (B777). Logical error, the signal does not change when extension is activated.

Overload system not working. All lift functions operate at reduced speed. 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 cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.

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

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

Check that cooler isn’t 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. Check cabling between the control unit and the component with diagnostic menu.

Workshop manual DRF 400–450

VDRF03.02GB

108

D Error codes – 8 Control system

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.

Overload system not working. All lift functions operate at reduced speed.

Check if there are error codes for sensors in the overload system.

-

OP, menu 1–5

8.2.1 Overload system

Redundant voltage feed left to Control unit, frame rear (D797-R) does not reach destination.

-

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

D797-R/K2:7

CAN/ POWER, menu 10

11.5.1.2 Redundant voltage feed of Control units

Redundant voltage feed right to Control unit, frame rear (D797-R) does not reach destination.

-

D797-R/K2:8

CAN/ POWER, menu 10

11.5.1.2 Redundant voltage feed of Control units

Incorrect power supply to Control unit, frame rear (D797-R). Voltage under 18 V or over 32 V.

-

D797-R/K2:1, K2:9, K2:10 – F58-2/3:1

CAN/ POWER, menu 10

11.5.1.3 Ignition voltage (15)

Incorrect power supply to Control unit, frame rear (D797-R).

-

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

8.2.1.5 Sensor, boom angle

Code

This error code cannot be removed with Reset. 151

152

153

154

155

VDRF03.02GB

Check the control unit. Check cabling between the control unit and the component with diagnostic menu. Check the control unit. Check fuse F58-2/3, change if needed. Check cabling between the control unit and the component with diagnostic menu. Check fuse F58-2/3, change if needed. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the sensor.

Workshop manual DRF 400–450

8.2.1.6 Sensor, boom length, (analogue sensor)

D Error codes – 8 Control system

Code

156

157

158

159

160

161

109

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit in the circuit for Cooling fan, hydraulic oil (M668).

Cooling fan hydraulic oil not working.

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

D797-R/ K1:14 – M668/1

HYD, menu 1

10.6.3 Cooling fan

The transistor has been triggered due to short circuit or open circuit in the circuit for 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

9.6.10 Working lights, boom

The transistor has been triggered due to short circuit or open circuit in the circuit for Lamp, working lights, boom, right front (E404-3R).

Working light, boom right not working.

Check bulb.

D797-R/ K1:15 – E4043R

LIGHTS, menu 3

9.6.10 Working lights, boom

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for Sensor, steering axle load (B7221L and B7221R).

Overload systems indicates overload.

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

D797-R/K1:2 – B7221L/A, B7221R/A

OP, menu 1

8.2.1.4 Sensor, steering axle load

Check the motor.

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

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

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

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

Check the sensor.

Workshop manual DRF 400–450

VDRF03.02GB

110

Code

162

163

164

165

166

167

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Sensor, position sensor boom length

Damping in/ out/1.5 m not working.

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

D797-R/K1:2 – B777/A, B769-3/A, B769-4/A

OP, menu 1

8.2.1.6 Sensor, boom length (position sensor)

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the component. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check bulb. Check the lamp holder. Check cabling between the control unit and the component with diagnostic menu.

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

168

169

170

171

172

173

111

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for Lamp, position light, left (H416-2).

Position light left rear not working.

Check bulb.

D797-R/K1:7 – H416-2/1

LIGHTS, menu 5

9.6.2 Running lights

The transistor has been triggered due to short circuit or open circuit in the circuit for Lamp, position light, right (H417-2).

Position light right rear not working.

Check bulb.

D797-R/K1:9 – H417-2/1

LIGHTS, menu 5

9.6.2 Running lights

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for Lamp, direction indicator, left rear (H426).

Direction indicator rear left not working.

D797-R/ K1:29 – H426/ 1

LIGHTS, menu 8

9.6.6 Direction indicators

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

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

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

Check the lamp holder. Check the lamp holder.

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

Workshop manual DRF 400–450

VDRF03.02GB

112

Code

174

175

178

183

184

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Lamp, direction indicator, right rear (H426).

Direction indicator rear right not working.

Check bulb.

D797-R/ K1:39 – H427/ 1

LIGHTS, menu 8

9.6.6 Direction indicators

Different signal from Sensor, steering axle 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 been triggered due to short circuit or open circuit in the circuit for Solenoid valve, pump unloading (Y6062).

Unloading of hydraulic oil pumps at boom not working.

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

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.

Overload system not working. All lift functions operate at reduced speed. Error code 150 is activated.

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

D797-R/ K1:21 – B771/ 3

OP, menu 4

8.2.1.5 Sensor, boom angle

Faulty signal from Sensor, boom length (B777). 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.

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

D797-R/ K1:22 – B777/ 3

OP, menu 4

8.2.1.6 Sensor, boom length

VDRF03.02GB

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

Check the sensor.

D797-R/ K1:12 – B7221R/C

Check the solenoid valve.

Check the sensor.

Check the sensor.

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

191

192

113

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in circuit for electromagnetic clutch of AC compressor (M677).

Air conditioning not working.

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

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

11.5.1.2 Redundant voltage feed of Control units

Check the component.

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 been triggered due to short circuit or open circuit in the circuit for Relay starter motor (K360). 197

High hydraulic oil temperature.

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

No limitation.

Check that cooling fan is working. Check that cooler isn’t 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 Ω.

Incorrect display of fuel amount (empty or full).

Check the sensor.

Redundant voltage feed left to Control unit, frame option (D797-O) does not reach destination.

-

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

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

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

Check the control unit.

Workshop manual DRF 400–450

VDRF03.02GB

114

Code

202

203

204

211

212

213

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Redundant voltage feed right to Control unit, frame option (D797-O) does not reach destination.

-

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

D797-O/K2:8

CAN/ POWER, menu 12

11.5.1.2 Redundant voltage feed of Control units

Incorrect power supply to Control unit, frame option (D797O). Voltage under 18 V or over 32 V.

-

D797-O/ K2:10 – F582/4:1

CAN/ POWER, menu 12

11.5.1.3 Ignition voltage (15)

Incorrect emergency stop switch voltage to Control unit frame option (D797-O).

Functions normally supplied emergency stop switch voltage have no 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 been triggered due to short circuit in the circuit for Solenoid valve, cab forward/up (Y6016).

Hydraulic cab sliding or liftable cab not working.

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

D797-O/K1:2 – Y6016/1

SLIDINGCAB, menu 3

9.10.4.3 Control valve option frame

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, cab backward/ down (Y6017).

Hydraulic cab sliding or liftable cab not working.

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, steering left (Y636L).

Joystick steering or mini-wheel not working.

VDRF03.02GB

Check the control unit. Check fuse F58-2/4, change if needed. Check cabling between the control unit and the component with diagnostic menu.

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

9.10.5.2 Control valve option frame

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

D797-O/K1:3 – Y6017/1

SLIDINGCAB, menu 4

9.10.5.2 Control valve option frame

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

Workshop manual DRF 400–450

9.10.4.3 Control valve option frame

D797-O/K1:4 – Y636L1/1

ELSTEERING, menu 4

5.2.10 Control valve joystick steering/miniwheel

D Error codes – 8 Control system

Code

214

215

216

217

115

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, steering right (Y636R).

Joystick steering or mini-wheel not working.

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

D797-O/K1:5 – Y636R1/1

ELSTEERING, menu 5

5.2.10 Control valve joystick steering/miniwheel

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, support jacks up, (Y6053).

Support jacks not working.

D797-O/ K1:30 – Y6063/1

SUPPORTJACKS, menu 3

7.10.1.2 Control valve option frame

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, support jacks down, (Y6064).

Support jacks not working.

D797-O/ K1:31 – Y6064/1

SUPPORTJACKS, menu 3

7.10.1.2 Control valve option frame

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

218

Solenoid valve, cab tilt down (Y6048).

Tiltable cab not working.

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

Workshop manual DRF 400–450

VDRF03.02GB

116

Code

220

221

237

238

239

240

D Error codes – 8 Control system

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.

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

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.

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

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 sliding or liftable cab not working.

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

D797-O/ K1:16 – Y6016/2

SLIDINGCAB, menu 3

9.10.4.3 Control valve option frame

Faulty signal from Solenoid valve, cab backward/down (Y6017). Return current does not match control current.

Hydraulic cab sliding or liftable cab not working.

Faulty signal from Solenoid valve, steering left (Y636L). Return current does not match control current.

Joystick steering or mini-wheel not working.

Faulty signal from Solenoid valve, steering right (Y636R). Return current does not match control current.

Joystick steering or mini-wheel not working.

VDRF03.02GB

Check the sensor.

7.10.1.6 Sensor, lowered support jacks

Check the sensor.

9.10.5.2 Control valve option frame

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

D797-O/ K1:17 – Y6017/2

SLIDINGCAB, menu 4

9.10.5.2 Control valve option frame

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

D797-O/ K1:18 – Y636L/2

ELSTEERING, menu 4

5.2.10 Control valve joystick steering/miniwheel

D797-O/ K1:19 – Y636R/2

ELSTEERING, menu 5

5.2.10 Control valve joystick steering/miniwheel

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

Workshop manual DRF 400–450

9.10.4.3 Control valve option frame

D Error codes – 8 Control system

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.

-

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

D791-1/K2:7

CAN/ POWER, menu 16

11.5.1.2 Redundant voltage feed of Control units

252

Redundant voltage feed left to frame control unit (D791-1) does not reach destination.

-

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

D791-1/K2:8

CAN/ POWER, menu 16

11.5.1.2 Redundant voltage feed of Control units

253

Incorrect power supply to attachment control unit (D791-1). Voltage under 18 V or over 32 V.

Functions normally supplied emergency stop switch voltage have no 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 stop switch voltage to Control unit, attachment (D791-1).

Functions normally supplied emergency stop switch voltage have no 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 been triggered due to short circuit or open circuit in the circuit for Lamp, working lights, 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 been triggered due to short circuit or open circuit in the circuit for Lamp, working lights, attachment left (E406L).

Working lights attachment left not working.

Check bulb.

D791-1/K1:15 – E406L

LIGHTS, menu 2

9.6.11 Working lights attachment

Code

254

257

258

Check fuse F52-1, change if needed. Check cabling between the control unit and the component with diagnostic menu.

Check fuse F52-1, change if needed. Check cabling between the control unit and the component with diagnostic menu.

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

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

Workshop manual DRF 400–450

VDRF03.02GB

118

Code

259

260

261

262

263

264

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Buzzer, automatic spreading 20’-40’ (H4009).

Automatic spreading 20'-40' not working.

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

D791-1/K1:28 – H9003/1

ATTACH, menu 15

7.5 Spreading

The transistor has been triggered due to short circuit or open circuit in the circuit for 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

9.6.11 Working lights attachment

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, rotation clockwise (Y6008).

Rotation of attachment not working.

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

D791-1/K1:2 – Y6008/1

ATTACH, menu 11

7.6.3 Control valve attachment

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, rotation anticlockwise (Y6009).

Rotation of attachment not working.

D791-1/K1:3 – Y6009/1

ATTACH, menu 12

7.6.3 Control valve attachment

The transistor has been triggered due to short circuit in the circuit for Solenoid 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 been triggered due to short circuit in the circuit for Solenoid 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 component.

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

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

265

266

267

268

269

270

119

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, side shift, right (Y6021).

Side shift of attachment not working.

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

D791-1/K1:30 – Y6021/1

ATTACH, menu 8

7.4.3 Control valve attachment

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for Solenoid valve, tilt lock 1 (Y6012-1).

Tilt locked, tilt damping and controllable tilt not working.

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

D791-1/K1:7 – Y6012-1/1

ATTACH, menu 15

7.7.4 Lock valve, tilt

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, tilt lock 2 (Y6012-2).

Tilt locked, tilt damping and controllable tilt not working.

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

D791-1/K1:9 – Y6012-2/1

ATTACH, menu 15

7.7.4 Lock valve, tilt

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

Check the solenoid valve.

Check the solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

120

Code

271

272

273

274

287

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in circuit for voltage feed to attachment position sensor.

Twistlocks, rotation stop, and spreading not working.

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

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 been triggered due to short circuit or open circuit in the circuit for Indicator light, open twistlocks (H562).

Indicator light, open twistlocks, not working.

Check bulb.

The transistor has been triggered due to short circuit or open circuit in circuit for alignment indicator light (H564).

Indicator light alignment twistlock not working.

Check bulb.

The transistor has been triggered due to short circuit or open circuit in the circuit for Indicator light, locked twistlocks (H563).

Indicator light, locked twistlocks, not working.

Check bulb.

Faulty signal from Solenoid valve, rotation clockwise (Y6008). Return current does not match control current.

Rotation of attachment not working.

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

VDRF03.02GB

Check the lamp holder.

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 (position sensor)

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

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

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

Check the solenoid valve.

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

288

289

290

298

299

300

121

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Faulty signal from Solenoid valve, rotation anticlockwise (Y6009). Return current does not match control current.

Rotation of attachment not working.

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

D791-1/K1:17 – Y6009/2

ATTACH, menu 12

7.6.3 Control valve attachment

Faulty signal from Solenoid valve, spreading out (Y6018). Return current does not match 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 not match control current.

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 cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check that Sensors twistlock are clean and correctly adjusted. Check cabling between the control unit and the component with diagnostic menu. Check that Sensors twistlock are clean and correctly adjusted. Check cabling between the control unit and the component with diagnostic menu. Check that the alignment sensors are clean and correctly adjusted. Check that alignment pin runs smoothly. Check cabling between the control unit and the component with diagnostic menu.

Workshop manual DRF 400–450

VDRF03.02GB

122

Code

301

302

303

304

311

312

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Redundant voltage feed left to Control unit, attachment option (D791-2) does not reach destination.

-

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

D791-2/K2:7

CAN/ POWER, menu 17

11.5.1.2 Redundant voltage feed of Control units

Redundant voltage feed left to Control unit, attachment option (D791-2) does not reach destination.

-

D791-2/K2:8

CAN/ POWER, menu 17

11.5.1.2 Redundant voltage feed of 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 stop switch voltage to 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 and F52-1, change if 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 been triggered due to short circuit in the circuit for Solenoid valve, levelling right (Y6035).

Levelling not working.

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

D791-2/K1:2 – Y6035/1

ATTACH, menu 19

7.8.3 Control valve attachment

The transistor has been triggered due to short circuit in the circuit for Solenoid 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 control unit. Check cabling between the control unit and the component with diagnostic menu. Check the control unit.

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

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

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

313

314

315

316

123

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, tilt out (Y6010).

Controllable tilt not working.

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

D791-2/K1:4 – Y6010/1

ATTACH, menu 16

7.7.5 Control valve attachment

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, tilt in (Y6011).

Controllable tilt not working.

D791-2/K1:5 – Y6011/1

ATTACH, menu 17

7.7.5 Control valve attachment

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, levelling lock(Y6034-1).

Levelling is locked, controllable levelling and float position not working.

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

D791-2/K1:30 – Y6034-1/1

ATTACH, menu 18

7.8.6 Valve block, levelling cylinders

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, levelling lock (Y6034-2).

Levelling is locked, controllable levelling and float position not working.

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

D791-2/K1:31 – Y6034-2/1

ATTACH, menu 18

7.8.6 Valve block, levelling cylinders

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

Check the solenoid valve.

Check the solenoid valve.

317

Incorrect output signal special function.

WARNING

D791-2/K1:32

318

Incorrect output signal special function.

WARNING

D791-2/K1:33

319

Incorrect output signal special function.

WARNING

D791-2/K1:7

320

Incorrect output signal special function.

WARNING

D791-2/K1:9

321

Incorrect output signal special function.

WARNING

D791-2/K1:10

322

Incorrect output signal special function.

WARNING

D791-2/K1:25

Workshop manual DRF 400–450

VDRF03.02GB

124

Code

337

338

339

340

351

352

353

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Faulty signal from Solenoid valve, levelling right (Y6035). Return current does not match control current.

Levelling not working.

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

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 match control current.

Levelling not working.

D791-2/K1:17 – Y6036/2

ATTACH, menu 18

7.8.3 Control valve attachment

Faulty signal from Solenoid valve, tilt out (Y6010). Return current does not match control current.

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 (Y6011). Return current does not match control current.

Controllable tilt not working.

D791-2/K1:19 – Y6011/2

ATTACH, menu 15

7.7.5 Control valve attachment

Redundant voltage feed left to Control unit, attachment left jack pair (D791-3) does not reach destination.

-

D791-3/K2:7

CAN/ POWER, menu 18

11.5.1.2 Redundant voltage feed of Control units

Redundant voltage feed right to Control unit, attachment left jack pair (D791-3) does not reach destination.

-

D791-3/K2:8

CAN/ POWER, menu 18

11.5.1.2 Redundant voltage feed of 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 cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the control unit. Check cabling between the control unit and the component with diagnostic menu. Check the control unit. Check fuse F58-3/1 and F52-2, change if needed. Check cabling between the control unit and the component with diagnostic menu.

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

354

357

358

360

361

362

125

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Incorrect emergency stop switch voltage to Control unit, attachment left jack pair (D791-3).

Functions supplied with emergency stop switch voltage lack feed. Left lifting jacks not working.

Check fuse F58-3/1 and F52-2, change if 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 been triggered due to short circuit or open circuit in the circuit for Working lights left lifting jacks (E404-6L).

Working lights left lifting jacks not working.

Check bulb.

D791-3/K1:1 – E404-6L/1

-

9.6.11 Working lights attachment

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, levelling lock(Y6034-1) and Solenoid valve, levelling lock(Y60342).

Levelling is locked, controllable levelling and float position not working.

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

D791-3/K1:15 – Y6034-1/1, Y6034-2/1

ATTACH, menu 18

7.8.6 Valve block, levelling cylinders

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, operating position (Y6053L).

Left lifting jacks not working.

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

D791-3/K1:42 – Y6053L/1

COMBI, menu 16

7.9.2.5 Valve, operating position

The transistor has been triggered due to short circuit in the circuit for Solenoid 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 been triggered due to short circuit in the circuit for Solenoid valve, levelling left (Y6036).

Levelling not working.

D791-3/K1:3 – Y6036/1

ATTACH, menu 20

7.8.3 Control valve attachment

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

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

Check the solenoid valve.

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

Workshop manual DRF 400–450

VDRF03.02GB

126

Code

363

364

365

366

367

368

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, front knee in (Y6057L).

Left lifting jacks not working.

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

D791-3/K1:4 – Y6057L/1

COMBI, menu 11

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, front knee out (Y6056L).

Left lifting jacks not working.

D791-3/K1:5 – Y6056L/1

COMBI, menu 10

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, rear knee in (Y6059L).

Left lifting jacks not working.

D791-3/K1:30 – Y6059L/1

COMBI, menu 13

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, rear knee out (Y6058L).

Left lifting jacks not working.

D791-3/K1:31 – Y6058L/1

COMBI, menu 12

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, lowering front jack (Y6013L).

Left lifting jacks not working.

D791-3/K1:32 – Y6013L/1

COMBI, menu 10

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, front jack up (Y6060L).

Left lifting jacks not working.

D791-3/K1:33 – Y6060L/1

COMBI, menu 11

7.9.2.3 Control valve, lifting jacks

VDRF03.02GB

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

369

370

371

372

373

374

127

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, lowering rear jack (Y6014L).

Left lifting jacks not working.

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

D791-3/K1:7 – Y6014L/1

COMBI, menu 12

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, rear jack up (Y6061L).

Left lifting jacks not working.

D791-3/K1:9 – Y6061L/1

COMBI, menu 13

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for 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 cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.

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

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

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

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

Workshop manual DRF 400–450

VDRF03.02GB

128

Code

375

376

377

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, clamp (Y6054L).

Left lifting jacks not working.

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

D791-3/K1:11 – Y6054L/1

COMBI, menu 15

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, clamp release (Y6055L).

Left lifting jacks not working.

D791-3/K1:12 – Y6055L/1

COMBI, menu 15

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the 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 not match control current.

Levelling not working.

Faulty signal from Solenoid valve, levelling left (Y6036). Return current does not match control current.

Levelling not working.

VDRF03.02GB

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

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

401

402

403

404

407

410

129

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Redundant voltage feed left to Control unit, attachment right jack pair (D791-4) does not reach destination.

-

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

D791-4/K2:7

CAN/ POWER, menu 19

11.5.1.2 Redundant voltage feed of Control units

Redundant voltage feed right to Control unit, attachment right jack pair (D791-4) does not reach destination.

-

D791-4/K2:8

CAN/ POWER, menu 19

11.5.1.2 Redundant voltage feed of 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 and F52-2, change if needed.

D791-4/K2:1 – F52-2 – F58-3/1

CAN/ POWER, menu 19

11.5.1.4 Emergency stop switch voltage

Incorrect emergency stop switch voltage to Control unit, attachment right jack pair (D791-4).

Control switch cannot be disengaged. Right lifting jacks and controllable tilt not working.

Check fuse F58-3/1 and F52-2, change if 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 been triggered due to short circuit or open circuit in the circuit for Working lights left lifting jacks (E404-6R).

Working lights left lifting jacks not working.

Check bulb.

D791-4/K1:1 – E404-6R

-

9.1.11 Working lights attachment

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, operating position (Y6053R).

Right lifting jacks not working.

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

D791-4/K1:42 – Y6053R/1

COMBI, menu 16

7.9.2.5 Valve, operating position

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

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

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

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

Check the solenoid valve.

Workshop manual DRF 400–450

VDRF03.02GB

130

Code

411

412

413

414

415

416

417

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, tilt out (Y6010).

Controllable tilt not working.

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

D791-4/K1:15 – Y6010/1

ATTACH, menu 16

7.7.5 Control valve attachment

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, tilt in (Y6010).

Controllable tilt not working.

D791-4/K1:15 – Y6011/1

ATTACH, menu 17

7.7.5 Control valve attachment

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, front knee in (Y6057R).

Right lifting jacks not working.

D791-4/K1:4 – Y6057R/1

COMBI, menu 11

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, front knee out (Y6056R).

Right lifting jacks not working.

D791-4/K1:5 – Y6056R/1

COMBI, menu 10

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, rear knee in (Y6059R).

Right lifting jacks not working.

D791-4/K1:30 – Y6059R/1

COMBI, menu 13

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit in the circuit for Solenoid valve, rear knee out (Y6058L).

Right lifting jacks not working.

D791-4/K1:31 – Y6058R/1

COMBI, menu 12

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, lowering front jack (Y6013R).

Right lifting jacks not working.

D791-4/K1:32 – Y6013R/1

COMBI, menu 10

7.9.2.3 Control valve, lifting jacks

VDRF03.02GB

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

Workshop manual DRF 400–450

D Error codes – 8 Control system

Code

418

419

420

421

422

423

131

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, front jack up (Y6060R).

Right lifting jacks not working.

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

D791-4/K1:33 – Y6060R/1

COMBI, menu 11

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, lowering rear jack (Y6014R).

Right lifting jacks not working.

D791-4/K1:7 – Y6014R/1

COMBI, menu 12

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, rear jack up (Y6061R).

Right lifting jacks not working.

D791-4/K1:9 – Y6061R/1

COMBI, menu 13

7.9.2.3 Control valve, lifting jacks

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 been triggered due to short circuit or open circuit in the circuit for Indicator light (H581).

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 been triggered due to short circuit or open circuit in the circuit for Indicator light (H578).

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

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

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

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

Workshop manual DRF 400–450

VDRF03.02GB

132

D Error codes – 8 Control system

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

The transistor has been triggered due to short circuit or open circuit in the circuit for Indicator light (H579).

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 been triggered due to short circuit or open circuit in the circuit for Solenoid valve, clamp (Y6054R).

Right lifting jacks not working.

D791-4/K1:2 – Y6054R

COMBI, menu 15

7.9.2.3 Control valve, lifting jacks

426

The transistor has been triggered due to short circuit or open circuit in the circuit for Solenoid valve, clamp release (Y6055R).

Right lifting jacks not working.

D791-4/K1:3 – Y6055R

COMBI, menu 15

7.9.2.3 Control valve, lifting jacks

427

The transistor has been triggered due to short circuit or open circuit in the circuit for 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 lamp holder. Check cabling between the control unit and the component with diagnostic menu.

Check cabling between the control unit and the component with diagnostic menu. Check the 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 Solenoid valve, tilt out (Y6010). Return current does not match control current.

VDRF03.02GB

Controllable tilt not working.

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

Workshop manual DRF 400–450

D791-4/K1:16 – Y6010/2

ATTACH, menu 16

7.7.5 Control valve attachment

D Error codes – 8 Control system

133

Description

Limitation

Action

Connections and components

Diagnostic menu

Group

Faulty signal from Solenoid valve, tilt in (Y6010). Return current does not match control current.

Controllable tilt not working.

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

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 not reach destination.

-

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

795/K1:7

CAN/ POWER, menu 14

11.5.1.2 Redundant voltage feed of Control units

452

Redundant voltage feed right to KID control unit (D795) does not reach destination.

-

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

795/K1:8

CAN/ POWER, menu 14

11.5.1.2 Redundant voltage feed of Control units

460

No messages received on CAN-buffer 1.

Incorrect values in operating menus.

Use diagnostic menu to 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.

Use diagnostic menu to 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.

Workshop manual DRF 400–450

VDRF03.02GB

134

D Error codes – 8 Control system

VDRF03.02GB

Workshop manual DRF 400–450

E Schematics

1

E Schematics

Table of Contents E Schematics mm mm mm mm mm mm

10

Common hydraulics....................................................................................... 3 Hydraulic diagrams, compilation ............................................................................ 3 Hydraulic diagram 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 oil pump alternative Rexroth) ............................................................... 24 Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Sauer-Danfoss) ................................................... 26 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 oil pump alternative Rexroth) ............................................................... 36 Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Sauer-Danfoss) ................................................... 38 Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Rexroth) ............................................................... 40 Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Sauer-Danfoss) ................................................... 42

11

Common electrics ........................................................................................ 44 Circuit diagram, description ................................................................................. 44 Component designations ...................................................................................... 46 Circuit diagrams, compilation ............................................................................... 46

Workshop manual DRF 400–450

VDRF03.02GB

2

VDRF03.02GB

E Schematics

Workshop manual DRF 400–450

E Schematics – 10 Common hydraulics

3

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

-

Workshop manual DRF 400–450

VDRF03.02GB

VDRF03.02GB

P

Workshop manual DRF 400–450

42

43

T

44

H

A

VA

H

2

D

S L1

X1

L2

B2

33 33

41

B1

40

38

36

B1

B1

A1

PS

L2

VA

B2

34

D

B2

32

VB

T

A2

5

L4

L3

X2

39

37

33

35

S L1

X1

L4 L3

33 X2

30

29

31 LS CF

P

PSS

47

VA

C-

T

T

4

T

33

D

C-

C+

P

LS

46 PP

45

C+

3

P

EF

28

VA

C+

PP

27

6

25

26

D

C-

T

24 L

T

P LS

M

17

7

R

P

B

B

PT

22

23

M

ACC

8

16

20

T

H

21

18

13

15 14

19

10

9 10

11

12

11

page –

010869 (A40740.0100 ver. 8)

1

4 E Schematics – 10 Common hydraulics

Hydraulic diagram base machine (hydraulic oil pump alternative Rexroth)

E Schematics – 10 Common hydraulics

1. Lift cylinder

25. Oil return from attachment

2. Valve block lift cylinder

26. Oil filter brake system

3. Extension cylinder

27. Oil filter

4. Valve block extension cylinder

28. Cooler hydraulic oil

5. Lift cylinder

29. Bypass valve, hydraulic oil cooler

6. Valve block lift cylinder

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

33. Non-return valve

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

41. Hydraulic oil pumps 1 and 2

18. Cooler brake system

42. Pressure limiting valve

19. Thermal bypass valve

43. Valve block pump unloading

20. Breather filter, brake fluid tank

44. Pressure reducer

21. Oil tank brake system

45. Servo pressure accumulator

22. Breather filter hydraulic oil tank

46. Servo filter

23. Steering valve

47. Control valve lifting/lowering and extension

5

24. Steering cylinder

Workshop manual DRF 400–450

VDRF03.02GB

VDRF03.02GB

P

Workshop manual DRF 400–450

1 3

42

43

2

T

44

H

A

H

45

B1

33 33

D

41

48

D

P

T

LS

46 PP

VA

C+

2

S L2 L1

1 3

37

38

392

40

PSS

T

X1

C-

3

36

B1

35

33

4

B1

VA

PS

A1

VA

C+

X1

32

VB

B2

S L2 L1

34

D

C-

T

A2

P

T

29 48

31

P

C+

PP

28

VB

LS CF EF

30

47

5

27

25

D

6

26

C-

T

T

P

23

24

22

P LS

M

17 ACC

7

M

B

8

16

20

T

H

21

18

13

15 14

19

10

9 10

11

12

11

page –

012445 [A40470.0400 ver 01]

1

6 E Schematics – 10 Common hydraulics

Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss)

E Schematics – 10 Common hydraulics

1. Lift cylinder

25. Oil return from attachment

2. Valve block lift cylinder

26. Oil filter brake system

3. Extension cylinder

27. Oil filter

4. Valve block extension cylinder

28. Cooler hydraulic oil

5. Lift cylinder

29. Bypass valve, hydraulic oil cooler

6. Valve block lift cylinder

30. Hydraulic oil fine-filter

7. Brake pressure accumulator

31. Priority valve

8. Brake valve

32. Oil pump brake system

9. Parking brake caliper

33. Non-return valve

10. Brake cylinder

34. Pressure supply to attachment

11. Wheel brake

35. Hydraulic oil pump 2

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

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

41. Hydraulic oil pump 1

18. Cooler brake system

42. Pressure limiting valve

19. Thermal bypass valve

43. Valve block pump unloading

20. Breather filter, brake fluid tank

44. Pressure reducer

21. Oil tank brake system

45. Servo pressure accumulator

22. Breather filter hydraulic oil tank

46. Servo filter

23. Steering valve

47. Control valve lifting/lowering and extension

24. Steering cylinder

48. High-pressure filter

Workshop manual DRF 400–450

7

VDRF03.02GB

8

E Schematics – 10 Common hydraulics

VDRF03.02GB

Workshop manual DRF 400–450

010516 (A40856.0100 ver. 2)

B1

S

L1

X1

L2

B2

7

P

T1

L4

1

X2

L3

LS

6

5

B

A

PP

CF

P

EF

TP

4

T

LS

L

P

3

2

T

R

LS

Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth)

page –

E Schematics – 10 Common hydraulics

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

Workshop manual DRF 400–450

9

VDRF03.02GB

10

E Schematics – 10 Common hydraulics

013012

8

7

B1

S

L2

X1

L1

P

T1

1

LS

6

5

B

A

PP

CF

P

EF

TP

4

T

LS

L

P

3

2

T

R

LS

Hydraulic diagram joystick control (hydraulic oil pump alternative Sauer-Danfoss)

page –

VDRF03.02GB

Workshop manual DRF 400–450

E Schematics – 10 Common hydraulics

1.

Control valve option frame

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

Workshop manual DRF 400–450

11

VDRF03.02GB

12

E Schematics – 10 Common hydraulics

Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth)

T2B

T3B

P2B A

C

B

L3

13

S L1 B1

P

1

14

B

P

VDRF03.02GB

Workshop manual DRF 400–450

010512 (A40853.0100 ver. 4)

L2

X1

C1-

PP

B2

T

C2+ C1+

2

L4

X2

C2-

T

T

A

12

1

10

11

T1

P1

3

B

A

3

4

B

A

5

5

B

9

A

B

6

A

7

LSPB

PS

8

TPB

8

page –

E Schematics – 10 Common hydraulics

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.

Control valve attachment

13

10. Filter hydraulic oil 11. Filter hydraulic oil (high-pressure filter) 12. Solenoid valve, engagement of hydraulic pressure 13. Shuttle valve 14. Hydraulic oil pumps 1 and 2

Workshop manual DRF 400–450

VDRF03.02GB

14

E Schematics – 10 Common hydraulics

Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss)

T2B

T3B

P2B

L1

12

L2

X1

3

1 2

13

16

B1

15 15

1

012496

B

P

P

C1-

PP

S

T

C2+ C1+

2

C2-

14

T

T

A

1

10

11

T1

P1

3

B

A

3

4

B

A

5

5

B

9

A

B

6

A

7

LSPB

PS

8

TPB

8

page –

VDRF03.02GB

Workshop manual DRF 400–450

E Schematics – 10 Common hydraulics

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.

Control valve attachment

15

10. Filter hydraulic oil 11. Filter hydraulic oil (high-pressure filter) 12. Valve block top lift hydraulics 13. Shuttle valve 14. Attachment relief valve 15. Non-return valve 16. Hydraulic oil pump 1

Workshop manual DRF 400–450

VDRF03.02GB

16

E Schematics – 10 Common hydraulics

T2B

P2B

TPB

L3 L4

T

B1

P

1

14

B

VDRF03.02GB

Workshop manual DRF 400–450

010514 (A40853.0200 ver. 5)

L2 S L1

X1

PP

B2

C2+ P

C1-

2

C1+ C2-

X2

T

T

13

A

12

1

11

10

T1

P1

B

3

A

3

4

B

A

B

5

5

A

9

B

6

A

7

B

A

8

LSPB

PS

8

T3B

Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Rexroth)

page –

E Schematics – 10 Common hydraulics

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.

Control valve attachment

17

10. Filter hydraulic oil 11. Filter hydraulic oil (high-pressure filter) 12. Solenoid valve, engagement of hydraulic pressure 13. Shuttle valve 14. Hydraulic oil pumps 1 and 2

Workshop manual DRF 400–450

VDRF03.02GB

18

E Schematics – 10 Common hydraulics

T2B

P2B

TPB

L2 L1

12 X1

3

13 2

S

1

013010

16

B1

15 15

P B

VDRF03.02GB

14

T PP

C2+ P

C1-

2

C1+ C2-

1

T

T

A

1

11

10

T1

P1

B

3

A

3

4

B

A

B

5

5

A

9

B

6

A

7

B

A

8

LSPB

PS

8

T3B

Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Sauer-Danfoss)

page –

Workshop manual DRF 400–450

E Schematics – 10 Common hydraulics

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.

Control valve attachment

19

10. Filter hydraulic oil 11. Filter hydraulic oil (high-pressure filter) 12. Valve block top lift hydraulics 13. Shuttle valve 14. Attachment relief valve 15. Non-return valve 16. Hydraulic oil pump 1

Workshop manual DRF 400–450

VDRF03.02GB

20

E Schematics – 10 Common hydraulics

T2

TP A

16

T

B

PP

C2+

P

A

B

VDRF03.02GB

Workshop manual DRF 400–450

010515 (A431213.0100 ver. 3)

13

L4 L3 B1

S

X1

L1 L2

B2

X2

11

10

12

T1

P1

B

1

P

C1-

2

C1+

A

C2-

T

T

A

1

B

A

14

9

3

B

3

4

15

B

14

5

5

A

6

B

7

A

8

8

PS

T3

Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alternative Rexroth)

page –

E Schematics – 10 Common hydraulics

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.

Control valve attachment

21

10. Solenoid valve, engagement of hydraulic pressure 11. Shuttle valve 12. Oil filter 13. Hydraulic oil pumps 1 and 2 14. Levelling cylinders 15. Valve block, levelling cylinders 16. Overcentre valve, levelling

Workshop manual DRF 400–450

VDRF03.02GB

22

E Schematics – 10 Common hydraulics

T2

TP B A

11

T

B

PP

C2+

P

A

B

VDRF03.02GB

Workshop manual DRF 400–450

013011

18

B1

17

17

16

S

L2

X1

L1

14

3

15

2

1

13

T1

P1

B

1

P

C1-

2

C1+

A

C2-

T

T

A

1

B

A

9

12

3

B

3

4

10

9

5

5

A

6

B

7

A

8

8

PS

T3

Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alternative Sauer-Danfoss)

page –

E Schematics – 10 Common hydraulics

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.

Levelling cylinders

23

10. Valve block, levelling cylinders 11. Overcentre valve, levelling 12. Control valve attachment 13. Oil filter 14. Valve block top lift hydraulics 15. Shuttle valve 16. Attachment relief valve 17. Non-return valve 18. Hydraulic oil pump 1

Workshop manual DRF 400–450

VDRF03.02GB

VDRF03.02GB

Workshop manual DRF 400–450

S

L1

X1

L2

B2

L4

L3

X2

010520 (A41791.0100 ver. 1 - part 1/3)

B1

15

T1

P1

010526:C

B

A

1

P

B

P

B

PP

C1-

2C1+

T

C2+

A

C2-

T

A

T

1

B

12

A

9

3

B

4

A

11

10

9

B

5

A

6

B

7

A

8

T3

T2

P2

TP

PS

010532:F

010532 :E

010532:D

page –

1413

010526:B

010526:A

24 E Schematics – 10 Common hydraulics

Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Rexroth)

E Schematics – 10 Common hydraulics

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.

Levelling cylinders

25

10. Valve block, levelling cylinders 11. Overcentre valve, levelling 12. Control valve attachment 13. Valve block top lift hydraulics 14. Shuttle valve 15. Hydraulic oil pumps 1 and 2

Workshop manual DRF 400–450

VDRF03.02GB

26

E Schematics – 10 Common hydraulics

Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Sauer-Danfoss)

T3

T2

010532:F P2

TP

A

11

12

A

T

A

A T

A

P

VDRF03.02GB

L1

3

13

Workshop manual DRF 400–450

013016

B1

16

15 15

S

L2

X1

14

010526:A

2

1

T1

P1

010526:B

010526:C

B

1

B

B

PP

C2+ P

C1-

2C1+

C2-

T

1

B

9

3

B

4

10

9

5

B

A

6

B

7

A

8

PS

010532:D

010532 :E

page –

E Schematics – 10 Common hydraulics

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.

Levelling cylinders

27

10. Valve block, levelling cylinders 11. Overcentre valve, levelling 12. Control valve attachment 13. Valve block top lift hydraulics 14. Shuttle valve 15. Non-return valve 16. Hydraulic oil pump 1

Workshop manual DRF 400–450

VDRF03.02GB

28

E Schematics – 10 Common hydraulics

Hydraulic diagram combi yoke (part 2 of 3)

page –

1

TP

P2

T2

Rexroth: 010520:A Sauer-Danfoss: 013016:A

T3

2 3

A

B

A

B

4

A

5 B

P T

A

B

6

A

7 8

B

A

B

10 P1

Rexroth: 010520:B Sauer-Danfoss: 013016B

VDRF03.02GB

Rexroth: 010520:C Sauer-Danfoss: 013016:C

Workshop manual DRF 400–450

010526 (A41791.0100 ver. 2 - part 2/3)

9

E Schematics – 10 Common hydraulics

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

Workshop manual DRF 400–450

VDRF03.02GB

30

E Schematics – 10 Common hydraulics

Hydraulic diagram combi yoke (part 3 of 3)

page –

Rexroth: 010520:D Sauer-Danfoss: 013016:D

T3

T2

TP

P2

1 2 A

3

B

A

B

4 A

5

B

6

A

B

7 8

A

B

10 P1 T1

Rexroth: 010520:E Sauer-Danfoss: 013016:E

VDRF03.02GB

Rexroth: 010520:F Sauer-Danfoss: 013016:F

Workshop manual DRF 400–450

010532 (A41791.0100 ver. 1 - part 3/3)

9

E Schematics – 10 Common hydraulics

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

Workshop manual DRF 400–450

VDRF03.02GB

32

E Schematics – 10 Common hydraulics

Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth)

VDRF03.02GB

Workshop manual DRF 400–450

010517 (A40855.0100 ver. 1)

B1

S

L1

X1

L2

B2

6

P

T1

L4

X2

L3

1

LS

5

4

3

B

A

TP

2

page –

E Schematics – 10 Common hydraulics

1.

Control valve option frame

2.

Hydraulic motor sliding cab

3.

Solenoid valve, engagement of hydraulic pressure

4.

Shuttle valve

5.

Shuttle valve option

6.

Hydraulic oil pumps 1 and 2

Workshop manual DRF 400–450

33

VDRF03.02GB

34

E Schematics – 10 Common hydraulics

Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss)

VDRF03.02GB

Workshop manual DRF 400–450

013013 (A54505.0100 ver. 1)

6

7

S

L2

L1

5

4

1

3

2

page –

E Schematics – 10 Common hydraulics

1.

Control valve option frame

2.

Hydraulic motor sliding cab

3.

Solenoid valve, engagement of hydraulic pressure

4.

Shuttle valve

5.

Shuttle valve option

6.

Hydraulic oil pump 1

7.

Non-return valve

Workshop manual DRF 400–450

35

VDRF03.02GB

36

E Schematics – 10 Common hydraulics

Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Rexroth)

3

4

L3

VDRF03.02GB

Workshop manual DRF 400–450

11 010518 (A43276.0100 ver. 1)

B1

S

L1

X1

L2

B2

P

T1

L4

X2

1

LS

9

10

8

B

7

A

B

A

T3

TP

6

5

2

3

4

page –

E Schematics – 10 Common hydraulics

1.

Control valve option frame

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.

Solenoid valve, engagement of hydraulic pressure

9.

Shuttle valve

37

10. Shuttle valve option frame 11. Hydraulic oil pumps 1 and 2

Workshop manual DRF 400–450

VDRF03.02GB

38

E Schematics – 10 Common hydraulics

Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Sauer-Danfoss)

3

4

013014

11

10

S

P

T1

L2

1

L1

LS

9

8

B

7

A

B

A

T3

TP

6

5

2

3

4

page –

VDRF03.02GB

Workshop manual DRF 400–450

E Schematics – 10 Common hydraulics

1.

Control valve option frame

2.

Accumulator

3.

Hydraulic cylinder support jacks

4.

Valve block support jacks

5.

Load control valve

6.

Hydraulic cylinder vertically adjustable cab

7.

Solenoid valve, engagement of hydraulic pressure

8.

Shuttle valve

9.

Shuttle valve option frame

39

10. Non-return valve 11. Hydraulic oil pump 1

Workshop manual DRF 400–450

VDRF03.02GB

40

E Schematics – 10 Common hydraulics

Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Rexroth)

3

VDRF03.02GB

Workshop manual DRF 400–450

010519 (A40854.0100 ver.1)

B1

S

X1

L1 L2

B2

9

P

T1

1

X2

L4 L3

LS

8

7

6

B

5

A

B

A

P

4

2

2

3

page –

E Schematics – 10 Common hydraulics

1.

Control valve option frame

2.

Hydraulic cylinder support jacks

3.

Overcentre valve support jacks

4.

Hydraulic motor sliding cab

5.

Restriction

6.

Solenoid valve, engagement of hydraulic pressure

7.

Shuttle valve

8.

Shuttle valve option

9.

Hydraulic oil pumps 1 and 2

Workshop manual DRF 400–450

41

VDRF03.02GB

42

E Schematics – 10 Common hydraulics

3

013015

9

8

S

P

T1

L2

1

L1

LS

7

6

B

5

A

B

A

P

4

2

2

3

Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Sauer-Danfoss)

page –

VDRF03.02GB

Workshop manual DRF 400–450

E Schematics – 10 Common hydraulics

1.

Control valve option frame

2.

Hydraulic cylinder support jacks

3.

Overcentre valve support jacks

4.

Hydraulic motor sliding cab

5.

Solenoid valve, engagement of hydraulic pressure

6.

Shuttle valve

7.

Shuttle valve option

8.

Non-return valve

9.

Hydraulic oil pump 1

Workshop manual DRF 400–450

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 connector’s number, e.g. XB72002Rm which is the connector for Sensor alignment front right (B7202R).

-XM674f

2

-X37-201

013017

2

Under the connector’s number the pin is specified with numbers or letters depending on the connector. •

X000-X199: In the cab.

•

X200-X299: On the frame.

•

X300-X399: On the boom.

•

X400-: On the attachment.

•

X37-: All grounding points start with X37, e.g. X37-201, which is a grounding point on the frame. X37-A, X37-B, X37-C and X37-D are grounding points in electronic box, cab. Zero references are in the control units.

Components Components 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

2

1 013018

1

•

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.

Workshop manual DRF 400–450

E Schematics – 11 Common electrics

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

5

1

013020

/9.10_1.A2

1

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 unit’s 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.

Workshop manual DRF 400–450

VDRF03.02GB

46

E Schematics – 11 Common electrics

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

B

Converter from non-electric to electric signals or vice versa. Example: inductive sensor.

D

Binary element, delay unit, memory. Example: control unit.

E

White light. Example: work lighting.

F

Protective device. Example: fuse.

G

Alternator, power supply device. Example: battery.

H

Signal device. Example: horn, brake lights.

K

Relay, contactor. Example: power relay ignition key lock.

M

Motor. Example: electric motor.

P

Measuring instrument, testing equipment. Example: operating hour gauge.

R

Resistor. Example: potentiometer.

S

Electric switch for control circuit, selector. Example: switch.

X

Outlet/socket, connecting device Example: connection terminal.

Y

Electrically controlled mechanical device: Example: solenoid valve, hydraulic valve.

Circuit diagrams, compilation

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

Circuit Dana TE 32000

VDRF03.02GB

Workshop manual DRF 400–450

E Schematics – 11 Common electrics

Sheet

Designation

2.0-3

Circuit Dana TE 32000

2.0-1A1

Circuit Dana TE 32000FF

2.0-2A2

Circuit Dana TE 32000FF

2.0-3A3

Circuit Dana TE 32000FF

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

Workshop manual DRF 400–450

47

VDRF03.02GB

48

E Schematics – 11 Common electrics

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

Circuit Extra Equipment

9.1-4

Circuit Sensor Instr.

9.1-5

Circuit Option Cab

9.1-6

Circuit Extra Equipment Boom nose

9.1-7

Circuit Extra Equipment

9.3-1

Circuit Cab Driver’s Seat

9.3-2

Circuit Cab Driver’s 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

Workshop manual DRF 400–450

E Schematics – 11 Common electrics

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

Workshop manual DRF 400–450

VDRF03.02GB

50

VDRF03.02GB

E Schematics – 11 Common electrics

Workshop manual DRF 400–450

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