manualshive.com logo in svg

Kalmar DCF 90-100, Руководство по ремонту, Страница: 1 / 992

Поделиться
Скачать
Kalmar DCF 90-100 Скачать руководство пользователя страница 1

A

Foreword

B

Safety

C 

Preventive maintenance

0 

Complete machine

1 

Engine

2 Transmission

3 

Driveline/axle

4 Br

akes

5 St

eering

6 

Suspension

7 L

oad handling

8 

Control system

9 

Frame, body, cab and accessories

10 

Common

 hydrauli

cs

11 

Common electrics

12 

Common

 pneumati

cs

D

Error codes

E

Schematics

F Te

chnical data

G Terminolog

y

 

and

 Index

Workshop 

manual

Содержание DCF 90-100

Страница 1: ...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 c...

Страница 2: ......

Страница 3: ...een different information types 4 Function group breakdown 5 Conditions 5 Storage 5 About the machine version 5 Copyright 5 Reading instructions 6 Warning information 6 Important information 6 Read th...

Страница 4: ...VDCF03 01GB Workshop Manual DCF 90 100 2 AForeword...

Страница 5: ...on 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 ea...

Страница 6: ...for the function in question From Component description or Function description to Diagnos tics to enable fast finding of the right diagnostic menu that can be used to check the component only applie...

Страница 7: ...ption page 24 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 stan...

Страница 8: ...nance manual The symbol to the left is used in certain cases on the machine and re fers to important information in the operator s maintenance manual page Optional equipment Indicates optional equipme...

Страница 9: ...ork togeth er Function descriptions describe the function in a logical flow from input signal to desired output signal Most functions require that preset con ditions are fulfilled for the function to...

Страница 10: ...tion lift and lower 4 Reference to description of component 5 Signal description reference value for signal out from component 6 Description of component s function 7 Position number reference to posi...

Страница 11: ...fixed displacement 8 Electrical motor 9 Accumulator 10 Disc brake 11 Filter 12 Radiator 13 Bulb 14 Control system two control units with CAN bus 15 Restriction 16 Adjustable restriction 17 Inductive p...

Страница 12: ...he 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 Supplem...

Страница 13: ...ect information Your feedback is important to be able to improve the information Copy this form write down your views and send it to us Thank you for your participation To Kalmar Industries AB Product...

Страница 14: ...VDCF03 01GB Workshop Manual DCF 90 100 12 A Foreword Feedback...

Страница 15: ...ydraulic and brake systems depressurizing 5 Oils 6 Fuel system 7 Clothing etc 8 Several mechanics on the same machine 8 Working under machine 9 Lifting heavy components 9 Vibrations 10 Noise 10 Solven...

Страница 16: ...VDCF03 01GB Workshop Manual DCF 90 100 2 BSafety...

Страница 17: ...se the correct equipment and tools for the job wear the correct clothes use common sense and work carefully Do not take any risks Kalmar Industries has in this publication documented and warned for si...

Страница 18: ...ire and explosion risks page 11 Fluid or gas under pressure page 12 Coolant page 13 Refrigerant page 14 Air pollution page 14 Tensioned springs page 15 Electric motors page 15 Rotating components and...

Страница 19: ...umulator Turn the main current on turn the starter key to position I and ac tivate the load handling functions several times 3 Turn the start key to position 0 and turn off the main electric pow er 4...

Страница 20: ...es and irrita tion The oil may also be corrosive to mucous mem branes in e g the eyes skin and throat IMPORTANT Always clean the area around components and con nections before they are loosened Dirt i...

Страница 21: ...ponent is to be disconnected hold a rag over the connection as protection and to collect fuel The en gine s fuel system operates at very high pressure The pressure is so high that the jet can injure t...

Страница 22: ...y 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 IMPORTANT...

Страница 23: ...s support under the frame or wheel axle Risks Mechanical or hydraulic tools and lifting devices can fall over or acci dentally be lowered due to malfunctions or incorrect use Safety precautions Use ax...

Страница 24: ...inders injuries may be sustained as vibrations can be trans mitted from tools to hands Especially when fingers are cold Safety precautions Use heavy gloves to protect against cold and somewhat against...

Страница 25: ...g 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...

Страница 26: ...pment or cause an explosion or fire Never weld on painted surfaces remove paint by blasting at least 10 cm around the welding or cutting point Use gloves breathing protec tion and protective goggles I...

Страница 27: ...ine high pres sure stream from a hydraulic hose can easily penetrate a hand and causes very severe injuries page Coolant The coolant in the machine s cooling system consists of water anti corrosion co...

Страница 28: ...on is the impurities in the air around us and which are regard ed as hazardous to health Certain pollution is more prominent in cer tain environments The following health hazardous air pollution is es...

Страница 29: ...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 a...

Страница 30: ...hed 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 work...

Страница 31: ...ith the machine s lift ing equipment in particular the greatest caution must be exercised with respect to securing the mast carriage and attachment Always make a habit of lowering the carriage to its...

Страница 32: ...ronmentally 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 a...

Страница 33: ...ations The machine does not contain asbestos The machine contains lead in batteries and electric cabling Some models have counterweights of cast lead If the machine is equipped with air conditioning t...

Страница 34: ...VDCF03 01GB Workshop Manual DCF 90 100 20 B Safety Environment...

Страница 35: ...kshop Manual DCF 90 100 C Preventive maintenance 1 C Preventive maintenance mm mm mm mm mm mm C Preventive maintenance page Preventive maintenance See Maintenance manual DCF 90 100 section C Preventiv...

Страница 36: ...VDCF03 01GB Workshop Manual DCF 90 100 2 C Preventive maintenance C Preventive maintenance...

Страница 37: ...m mm Table of Contents 0 Complete machine Complete machine 3 Complete machine description 3 Troubleshooting general work instructions 4 Troubleshooting without an error code example 5 Troubleshooting...

Страница 38: ...VDCF03 01GB Workshop Manual DCF 90 100 2 0 Complete machine...

Страница 39: ...ting attachment fastened to a lifting carriage that sits on a mast Load handling is divided into the functions lifting lowering tilt side shift spreading levelling and load securing Lifting lowering i...

Страница 40: ...nted directly using func tion descriptions Sections 0 12 contain descriptions of the various functions of the machine Troubleshooting procedure 1 Check that there is battery voltage available Battery...

Страница 41: ...es the signal page Troubleshooting with error code example Error codes are strong indicators of malfunctions detected by the con trol system Many error codes are connected to electrical malfunctions b...

Страница 42: ...ydraulic 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 di...

Страница 43: ...uestion 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 t...

Страница 44: ...respondingly 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...

Страница 45: ...5 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...

Страница 46: ...VDCF03 01GB Workshop Manual DCF 90 100 2 1Engine...

Страница 47: ...e alternatives this is written in brackets after headings or under figures to clarify that which is shown Component supplier documentation The Workshop manual only describes components and work descri...

Страница 48: ...15 18 21 17 3 12 14 23 19 13 16 SENSORS 9 7 M D793 D790 2 D795 D797 1 D794 D790 1 D1 D7 D8 D16 D12 D10 D11 D19 D14 D5 D4 Pos Explanation Signal description Reference 1 The ignition switch S150 sends...

Страница 49: ...ngine Starter motor description Volvo engine page 39 D8 Diagnostic menu see section 8 Control sys tem group 8 4 6 5 ENGINE menu 5 9 The engine s sensors send signals to the engine control unit D794 wh...

Страница 50: ...unit D795 shows fuel level in the operating menu for engine and transmission See section 11 Common electrics group 11 5 3 12 KID control unit D795 19 Speed limitation The output shaft speed sensor B7...

Страница 51: ...ensor 11 Coolant pump 2 Solenoid valve EGR 12 Sensor oil pressure 3 Crankcase ventilation 13 Oil filter 4 Injector and preheating 6 pcs 14 Sensor fuel pressure 5 Turbo 15 Fuel filter 6 Filling point e...

Страница 52: ...hop Manual DCF 90 100 8 1 Engine 1 Engine Volvo TAD760VE right side in machine s direction of travel 010198 1 2 3 4 5 1 Oil plug 4 Sensor crankshaft rpm 2 Starter motor M654 5 Thermostat housing 3 Dra...

Страница 53: ...g see section B Safety 1 Machine in service position see section B Safety 2 Attach hoisting equipment to the engine 3 Disconnect required hoses and cables before separating engine and transmission NOT...

Страница 54: ...nut to be removed from the flex plate 8 Take up the slack in the hoisting equipment NOTE Do not lift the engine 9 Remove the screws between engine and gearbox 10 Remove the screws in the engine brack...

Страница 55: ...ection both on the engine and the gearbox 14 Insert two studs into the flywheel housing as a guide when the en gine is installed 15 Transfer the engine brackets to the new engine tighten to 169 Nm oil...

Страница 56: ...etween the en gine and gearbox to facilitate installation of the nuts for the flex plate flywheel 19 Fit the nuts that fix the flex plates at the flywheel in two steps First fit the nuts without tight...

Страница 57: ...ine bracket Tighten to 169 Nm oiled screw 23 Fit the cover washer under the flywheel 24 Remove the hoisting equipment from the engine 25 Remove the jack from underneath the gearbox 26 Connect the requ...

Страница 58: ...0 1 D1 D7 D8 D16 D19 D12 D14 D10 D11 D5 D4 Pos Explanation Signal description Reference 1 The ignition switch S150 sends a voltage signal to cab control unit KCU D790 1 when the start key is turned to...

Страница 59: ...tarter motor description Cummins engine page 39 D8 Diagnostic menu see section 8 Control sys tem group 8 4 6 5 ENGINE menu 5 9 The engine s sensors send signals to the engine control unit D794 which r...

Страница 60: ...group 11 5 3 2 Frame control unit D797 1 18 The KID control unit D795 shows fuel level in the operating menu for engine and transmission See section 11 Common electrics group 11 5 3 12 KID control uni...

Страница 61: ...s direction of travel 009440 16 15 14 9 11 10 8 7 12 13 6 3 4 5 1 2 1 Hole for flex plate 9 Coolant inlet 2 Flywheel 10 Oil cooler 3 Crankcase ventilation 11 Oil filter 4 Injector drainage 12 Turbo in...

Страница 62: ...9 8 10 11 1 Drive belt tensioner 9 Fuel pressure sensor in rail 2 Coolant pump 10 Fuel rail 3 Fan drive 11 Pressure reducing valve in rail 4 Air inlet 12 Fuel filter 5 Coolant temperature sensor 13 Di...

Страница 63: ...section B Safety 2 Attach hoisting equipment to the engine 3 Disconnect required hoses and cables before separating engine and transmission NOTE Drain and collect liquids before detaching hoses 4 Rem...

Страница 64: ...d gearbox 10 Remove the screws in the engine brackets 11 Carefully detach the gearbox from the engine 12 Withdraw the engine rearwards to separate it from the gearbox NOTE Beware of balance before the...

Страница 65: ...lation of the screws for the flex plate flywheel 19 Remove the stud through the hole in the flywheel housing 20 Fit the screws that fix the flex plates at the flywheel in two steps First fit the screw...

Страница 66: ...Fit the screws in the engine bracket Tighten to 169 Nm oiled screw 24 Fit the cover plug in front of the flywheel 25 Remove the hoisting equipment from the engine 26 Remove the jack from underneath t...

Страница 67: ...engine s intake air is manually heated to a suitable temperature with glow plugs in each cylinder on Volvo engines Cummins engines are heated automatically with a heating coil The preheating lamp is...

Страница 68: ...Pull one edge of the cover away to facilitate access to the accel erator pedal 3 Unplug the cable from the connector 4 Unscrew the connector from the accelerator pedal 5 Replace the accelerator pedal...

Страница 69: ...ed of water For component locations see the section 1 Engine 1 2 1 Fuel tank page Fuel tank description The fuel tank is located on the left hand side of the machine behind the brake fluid reservoir 1...

Страница 70: ...on the engine side of the filter When the filter is clogged the vacuum pres sure increases and the indicator indicates that it s time to replace filter As an option the machine can be equipped with a...

Страница 71: ...r description Radiator core 1 Transmission oil cooler 2 Fuel cooler 3 Radiator engine 4 Intercooler 5 Expansion tank 6 Attachment condenser to AC The charge air is cooled by an air air intercooler in...

Страница 72: ...in the engine Transmission oil cooler part of radiator assembly lower Intercooler part of radiator assembly upper Fuel cooler located behind the radiator How the engine cooling system works 1 Coolant...

Страница 73: ...C Radiator for the engine is located in the cooler unit which is placed be hind the engine The purpose of the cooler assembly is to cool Engine coolant Gearbox oil cooled in the lower part of the radi...

Страница 74: ...Drift 1 Machine in service position see section B Safety 2 Slacken the belt tensioner and lock it in place with a drift or the like position 1 1 Coolant pump 3 Remove the belt from the coolant pump fi...

Страница 75: ...the belt tensioner and check that the belt is correctly posi tioned in the groove and is correctly tensioned 1 7 7 Coolant page Changing coolant and cleaning the cooling system Volvo engine Cooling pe...

Страница 76: ...continue with step 10 Cleaning with coolant 6 Fill the cooling system with 15 20 concentrated coolant mix ture Only use recommended concentrated coolant mixed with clean water 7 Drain the cooling sys...

Страница 77: ...ngine is completely bled free from air and filled with coolant Open any breather valves for a time after start so that any trapped air can escape Open all heat controls on the heater so that it is ble...

Страница 78: ...block 3 Check that all coolant drains NOTE There may be deposits inside the tap or the plug These must be cleaned away otherwise there is a risk that coolant may remain and cause freezing damage Check...

Страница 79: ...sure that the system is properly bled during filling NOTE Do not fit the cap 9 Start and run the engine for 5 minutes with coolant temperature over 80 C Switch off the engine and drain the cooling sys...

Страница 80: ...fety instructions for coolant before starting work see section B Safety Mix 40 glycol 60 water This mixture protects against internal corrosion cavitation and freez ing down to 28 C At 60 glycol mixtu...

Страница 81: ...NO normally open switch coolant level description The coolant level NO switch is located on the expansion tank 1 7 10 Engine heater page Engine heater description See supplier documentation engine A s...

Страница 82: ...90 100 38 1 Engine 1 9 Control system engine 1 9 Control system engine 1 9 1 Control unit engine page Engine control unit general See section 11 Common electrics group 11 5 3 10 Engine control unit an...

Страница 83: ...y on the starter motor solenoid is activated by the frame control unit D797 1 The signal can be checked from the diagnostic menu see section 8 Control system group 8 4 6 5 ENGINE menu 5 For more infor...

Страница 84: ...VDCF03 01GB Workshop Manual DCF 90 100 40 1 Engine 1 11 2 Stopping device...

Страница 85: ...2 1 1 Gear selector and multi function lever 18 2 2 Torque converter Clutch system 19 2 2 1 Flex plates 19 2 6 Lubrication system 21 2 6 3 Oil cooler 24 2 6 4 Oil filter 26 2 7 Cooling system 27 2 7 3...

Страница 86: ...VDCF03 01GB Workshop Manual DCF 90 100 2 2Transmission...

Страница 87: ...describes components and work descrip tions that concern installation in the machine For descriptions of and instructions for the transmission s components and systems refer to the supplier documentat...

Страница 88: ...ation Signal description Reference 1 The multi function lever S162 sends a voltage signal to the KIT control unit D790 2 Forward Conn F U 24 V Reverse Conn R U 24 V Gear and multi function lever descr...

Страница 89: ...Diagnostic menu See Section 8 Control system group 8 4 7 6 TRANSM menu 6 and 8 4 7 10 TRANSM menu 10 10 The transmission control unit D793 supplies voltage to valve block trans mission control to obta...

Страница 90: ...ontrol unit D795 20 If the signal from the output shaft speed sensor B758 indicates that machine speed exceeds the speed limitation the transmission control unit D793 transmits a engine speed reductio...

Страница 91: ...seat sensor S230 sends a voltage signal to the cab control unit D790 1 U 24 V Section 9 Frame body cab and accessories group 9 3 14 Operator in seat sensor D27 Diagnostic menu see section 8 Control sy...

Страница 92: ...e resistance through the filter becomes too high Opening pressure 390 kPa 5 The pressure governor releases pressure to the torque converter if the pressure be comes too high Opening pressure 2500 2900...

Страница 93: ...e sends signal to the control unit to verify that drive clutches for travel di rection and gear selection are activated when solenoid valve neutral position RSP Y6066 is activated 18 Solenoid valve VF...

Страница 94: ...to the transmission 27 The transmission oil cooler cools the oil 28 The bypass valve torque converter leads the oil past the torque converter if the pres sure becomes too high Opening pressure 400 kP...

Страница 95: ...ut from transmission 12 Radiator inlet 3 Oil pump transmission 13 Radiator outlet 4 Power take off 14 Transmission oil cooler 5 Radiator core 15 Radiator connection from radiator to sump 6 Thermostat...

Страница 96: ...690 7 Declutch pedal S220 1 2 Multi function lever S162 8 Transmission control unit D793 3 Control unit KIT D790 2 9a Control unit Volvo engine D794 4 Control unit KID D795 9b Control unit Cummins eng...

Страница 97: ...for oil before working see section B Safety 1 Machine in service position see section B Safety 2 Remove the propeller shaft from the transmission 3 Detach relevant hoses and cables before separating...

Страница 98: ...lex plate through the hole under the cov er washer NOTE Turn the engine for each nut to be removed from the flex plate 6 Attach the transmission to an overhead crane 7 Support the engine from undernea...

Страница 99: ...gine 10 Carefully separate the transmission and engine NOTE Check the balance of the gearbox before lifting it NOTE If the flex plates are damaged during gearbox replacement they must be replaced 11 R...

Страница 100: ...e a stud on the flywheel so that it aligns with the hole in the flywheel housing 16 Lift the gearbox into place Make sure that the studs on the fly wheel come into correct alignment and do not damage...

Страница 101: ...to the flex plate 19 Tighten the screws which fix the gearbox and engine 20 Measure and check that the gearbox is centred in the frame 21 Screw the gearbox into the gearbox mountings Tighten to 169 N...

Страница 102: ...r and multi function lever description Travel direction is selected with the gear and multi function lever Selection of travel direction F Forward N Neutral R Reverse The switch is supplied voltage by...

Страница 103: ...verter Clutch system 2 2 1 Flex plates page Flex plates changing 1 Machine in service position see section B Safety 2 Remove the gearbox see Gearbox replacement page 13 Fastening the flex plate TE1731...

Страница 104: ...and engine al ternatives 4 Replace the flex plate Tighten the screws fixing the flex plate to the transmission to 40 Nm oiled screws 5 Reinstall the gearbox see Gearbox replacement page 13 6 Before t...

Страница 105: ...3 The clutch plates require just a small amount of the oil flow supplied by the pump The remainder of the oil is pumped through the torque converter circuit to the oil cooler and re turns to the gear...

Страница 106: ...ent on and start the engine Allow the engine to idle for at least two minutes 8 Check the transmission oil level with the engine running at idle and top up to the marking for low level 9 Check that th...

Страница 107: ...engine at idle transmission in neutral position and at operating temperature approx 60 65 C The dipstick has two markings MAX and MIN The oil level should be at MAX Wipe off the dipstick before checki...

Страница 108: ...transmission oil is cooled in the lower section of the cooler unit A temperature controlled bypass valve which only acts on the trans mission oil cooling circuit is located in a pipe on the underside...

Страница 109: ...ransmission oil changing page 21 3 Loosen the cover plug and remove the thermostat 4 Check the O ring and the spring in the bottom change as need ed 5 Install the new thermostat and the cover plug 6 F...

Страница 110: ...ction B Safety 2 Remove the oil filter with the filter tool 3 Lubricate the O ring on the new oil filter with transmission oil 4 Install the new filter on the gearbox Tighten to contact and then anoth...

Страница 111: ...VDCF03 01GB Workshop Manual DCF 90 100 2 Transmission 2 7 Cooling system 27 2 7 Cooling system 2 7 3 Oil cooler page Oil cooler description See Oil cooler description page 24...

Страница 112: ...m wheel brake 2 Brake cooling connection return to radiator and tank 3 Brake cooling connection to wheel brake 4 Brake cooling connection from accumulator charg ing valve 5 Brake cylinder connection t...

Страница 113: ...VDCF03 01GB Workshop Manual DCF 90 100 2 Transmission 2 8 3 Transmission cable harness 29 2 8 3 Transmission cable harness page Transmission cable harness description See section E Schematics...

Страница 114: ...VDCF03 01GB Workshop Manual DCF 90 100 30 2 Transmission 2 8 3 Transmission cable harness...

Страница 115: ...VDCF03 01Gb Workshop Manual DCF 90 100 3Driveline Axle 1 3 Driveline Axle mm mm mm mm mm mm Table of Contents 3 Driveline Axle 3 Driveline axle 3 3 2 Propeller shaft 3 3 3 Drive axle 4...

Страница 116: ...VDCF03 01Gb Workshop Manual DCF 90 100 2 3Driveline Axle...

Страница 117: ...haft has two joints which means that the engine and drive axle can move in relation to each other page Propeller shaft replacement 1 Machine in service position see section B Safety 2 Clean the contac...

Страница 118: ...e only used in exceptional cases If information about a component is missing use the supplier documentation page Drive axle replacement 1 Remove the mast see section 7 Load handling group 7 2 Lifting...

Страница 119: ...g axle and frame 1 Hydraulic hoses 2 Cables 6 Disconnect hydraulic hoses position 1 and cabling position 2 from the distribution block NOTE Plug all unions at once to protect the hydraulic system from...

Страница 120: ...tion 6 from the parking brake NOTE Plug all unions at once to protect the hydraulic system from contamination Securing propeller shaft 10 Disconnect the propeller shaft from the drive axle Secure the...

Страница 121: ...he frame 15 Lift away the drive axle 16 Undo the hydraulic hoses on the drive axle NOTE Plug all unions at once to protect the hydraulic system from contamination 17 Transfer the couplings from the ol...

Страница 122: ...to the drive wheels 21 Clean the contact surfaces on the drive axle and frame Also clean the bolts contact surface on the drive axle s underside 22 Remove the nuts for attaching the drive axle blow c...

Страница 123: ...with suitable paint 28 Connect hydraulic hoses position 1 and cabling position 2 to the distribution block 29 Connect the hydraulic hose to the parking brake adjust the park ing brake 30 Connect the p...

Страница 124: ...VDCF03 01Gb Workshop Manual DCF 90 100 10 3 Driveline Axle 3 3 Drive axle...

Страница 125: ...5 4 3 9 Wheel brake 27 4 3 10 Pipes and hoses 29 4 5 Parking brake system 30 4 5 1 Hydraulic oil pump 33 4 5 2 Oil filter 33 4 5 3 M valve parking brake 33 4 5 4 Parking brake unit 34 4 5 5 Parking br...

Страница 126: ...VDCF03 01GB Workshop Manual DCF 90 100 2 4Brakes...

Страница 127: ...stration shows a loose brake pedal 2 Check that the brake pedal springs back adequately and that the clearance between brake pedal and brake valve is 1 1 5 mm If needed adjust the brake pedal s stop b...

Страница 128: ...al bracket 5 Detach the steering valve from the pedal bracket Secure the steering valve on the cab s underside Remove the steering valve s attaching bolts Pull down the valve slightly so that the stee...

Страница 129: ...4 1 1 Brake pedal 5 14 Close the drain valve on the accumulator charging valve NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring 15 Grease and adjust the brake peda...

Страница 130: ...er cleans the oil Hydraulic oil filter description page 39 3 The accumulator charging valve di rects oil to charging of accumula tors or through the brake system s cooling circuit Charge P 20 5 0 5 MP...

Страница 131: ...switch description page 24 D9 Diagnostic menu see section 8 Control system group 8 4 5 4 HYD menu 4 10 The frame control unit D797 1 transmits the brake light request on the CAN bus Controlled by cont...

Страница 132: ...itions 008061 1 2 3 4 5 6 7 8 9 10 11 12 1 Brake lights H411L and H411R 7 NC switch brake pressure S204 2 Control unit KIT D790 2 8 Distribution block drive axle 3 Brake valve 9 NO switch brake lights...

Страница 133: ...g The switchover between power generation and flow is regulated by the accumulator charging valve see Accumulator charging valve description page 12 For a description of how a gear pump works see sect...

Страница 134: ...pressure during cooling During cooling the pressure should be max 0 10 0 15 MPa at max engine rpm 8 Stop the engine 9 Depressurize the hydraulic systems See section B Safety 10 Remove the pressure gau...

Страница 135: ...ulic systems See section B Safety 19 Remove the pressure gauge and fit the protective cap on the measuring outlet 20 Close the drain valve on the accumulator charging valve NOTE Check that the accumul...

Страница 136: ...tem cooler The accumulator charging valve prioritises charging of the accumula tors above cooling A restriction of the charging means that a small quantity of oil also flows to cooling during accumula...

Страница 137: ...ing page 9 Adjusting screw accumulator charging pressure 3 If necessary adjust the accumulator charging pressure on the pressure limiting valve Undo the lock nut and adjust the pressure by turning the...

Страница 138: ...protect the brake sys tem from impurities 6 Remove the accumulator charging valve 7 Transfer the connection adapters and sensors to the new accu mulator charging valve 8 Fit the new valve 9 Connect th...

Страница 139: ...ses When the hy draulic system requires supply from the accumulator the diaphragm forces the oil back into the system Pressurised oil from the accumulator is used for the service and park ing brake sy...

Страница 140: ...distribution block with a plug that can han dle high pressure Plug the connection on the accumulator to pre vent contamination 7 Connect a pressure gauge 0 25 MPa to the measuring outlet for accumulat...

Страница 141: ...n nections Connect one of the other accumulators to the distribu tion block 15 Repeat steps 8 14 until all accumulators have been checked 16 Depressurize the hydraulic systems See section B Safety Ins...

Страница 142: ...Detach the accumulator from the distribution block NOTE Hold the block firmly so that the other accumulator does not work loose 6 Bend the clamp away and remove the accumulator 7 Fit the new accumula...

Страница 143: ...the cab under neath the brake pedal controls the hydraulic pressure to the brakes A lever transfers pedal force to the valve The brake valve is a mechanically activated proportional valve This means...

Страница 144: ...charged and the accumulator charging valve changes to cooling 7 Press down the pedal completely and read off the pressure Compare to the pressure plate on the left frame member 8 Stop the engine 9 Dep...

Страница 145: ...Plug the connections immediately to protect the brake sys tem from impurities 4 Secure the brake valve under the cab 5 Remove the brake valve attaching bolt 6 Remove the brake valve 7 Transfer the con...

Страница 146: ...t the accumulator drain valve is fully closed and tighten the lock ring 12 Turn on the main electric power and start the engine Run the en gine at idling speed 13 Test the brakes a couple of times 14...

Страница 147: ...s oil flow and brake pressure to the right and left hand wheel brakes The drive axle block is located on a brack et above the drive axle differential The drive axle block has a measuring outlet for br...

Страница 148: ...re the voltage signal to frame control unit D797 1 is cut off The signal can be checked from the diagnostic menu see tab 8 Con trol system group 8 4 5 4 HYD menu 4 page Break contact brake pressure ad...

Страница 149: ...mally open NO brake lights description The brake light NO switch controls brake light activation when the ma chine brakes The switch is located on the drive axle block which sits on a bracket above th...

Страница 150: ...t 1 Activated contact brakes applied 9 Press down the brake pedal slowly until the brake light is activat ed or the status of the input signal changes Keep the pedal in this position and check the pre...

Страница 151: ...brakes WDB Wet disc brakes require minimal maintenance and have a long service life due to effective cooling Maintenance requirements are minimised since oil circulates in the brake system and prevent...

Страница 152: ...ss down on the brake pedal keep the pedal pressed down 4 Open the bleed nipple and allow oil to run out of it until the oil is free of air bubbles NOTE The hydraulic hose between the brake pedal and b...

Страница 153: ...er pressing together the discs This creates friction between the discs that are fixed to the axle and those fixed to the hub reduction 4 3 9 2 Brake cylinder page Brake cylinder description Brake cyli...

Страница 154: ...rging valve directs oil to charging of accumulators or through the brake system s cooling circuit Charge P 20 5 0 5 MPa Cooling P 0 1 MPa Accumulator charging valve description page 12 4 The accumulat...

Страница 155: ...king brake description page 33 9 The brake caliper is drained of pressure and the spring applies the parking brake 0 MPa Parking brake unit description page 34 10 The parking brake NC switch S200 clos...

Страница 156: ...1 2 3 4 5 7 8 9 10 11 12 6 1 Control unit cab D790 1 7 Switch NO parking brake S200 2 Control unit KIT D790 2 8 Parking brake disc 3 Switch parking brake S107 9 Parking brake caliper 4 Frame control...

Страница 157: ...is terminated In stead a connection between the parking brake calliper and tank is opened and the parking brake applied This means that the parking brake is applied if the machine loses electrical pow...

Страница 158: ...before the pressure drops so low that the parking brake is applied If the parking brake is applied while the machine is on the move the brake disc and brake pads must be checked and re placed if nece...

Страница 159: ...ustment screw as well it must be held still when tightening the lock nut 11 Refit the cover to the caliper 12 Test the operation of the parking brake 4 5 4 1 Parking brake caliper page Brake calliper...

Страница 160: ...1 Machine in service position and wheels blocked see section B Safety 2 Remove the cover from the brake caliper 3 Undo the lock nut 4 Slacken the adjusting screw to release the brake pads 5 Remove th...

Страница 161: ...applied or released The NC switch sits on the accumulator charging valve which sits on the lifting beam in front of the gearbox in the engine compartment see Accumulator charging valve description pag...

Страница 162: ...hydraulics group 10 3 1 Hydraulic oil tank 002611 3 1 2 5 4 P T C C Pos Explanation Signal description Reference 1 The hydraulic oil pump pumps oil from the hydraulic oil tank See pressure plate on l...

Страница 163: ...lve description See section 10 Common hydraulic group 10 6 5 Radiator bypass valve 4 8 9 Cooling fan page Cooling fan description See section 10 Common hydraulics group 10 6 3 Cooling fan 4 8 10 Senso...

Страница 164: ...VDCF03 01GB Workshop Manual DCF 90 100 40 4 Brakes 4 8 14 Hydraulic oil 4 8 14 Hydraulic oil page Hydraulic oil description See section 10 Common hydraulics group 10 6 8 Hydraulic oil...

Страница 165: ...nts 5 Steering 5 Steering 3 5 2 Power assisted system 3 5 2 1 Hydraulic oil pump 5 5 2 2 Priority valve 6 5 2 3 Steering valve 8 5 2 4 Steering cylinder 10 5 2 5 Steering axle cradle 12 5 2 6 Link arm...

Страница 166: ...VDCF03 01GB Workshop Manual DCF 90 100 2 5Steering...

Страница 167: ...ises pressure supply to the steering valve over the working hydraulics The priority valve also transmits a control signal to the hy draulic oil pump Checked by control sys tem error shown with er ror...

Страница 168: ...ng valve pumps pressurised oil to the steering cylinder and transmits a load signal to the main pump Steering valve description page 8 6 The steering cylinder turns the wheels Steering cylinder descri...

Страница 169: ...s operating temperature 50 C 2 Machine in service position see section B Safety Measuring outlet on hydraulic oil pump for steering and load handling 3 Connect the pressure gauge to the measuring outl...

Страница 170: ...circuit The priority valve is load sensing and pilot pressure compensating Load sensing means that the valve adapts the control signal to the steering valve s consumption Pilot pressure compensating...

Страница 171: ...alve NOTE Transfer one connection at a time so that the marking is not mixed up 9 Connect the new priority valve to control valve lift and lower 10 Fit the priority valve attaching bolts 11 Connect th...

Страница 172: ...e gear pump to the distribution valve which guides oil to the steering cylinder The gear pump ensures that the oil flow fed to the cylinder is proportional to the steering wheel angle There are double...

Страница 173: ...e NOTE Transfer one at a time so that the marking is not mixed up 8 Connect the hydraulic hoses to the steering valve in accordance with the marking NOTE Check that the O rings are intact and are fitt...

Страница 174: ...n the wheels via the link arms The steer ing cylinder is a double acting hydraulic cylinder page Steering cylinder replacement NOTE Read the safety instructions for oil before working see section B Sa...

Страница 175: ...ing cylinder 6 Remove the steering cylinder s attaching bolts 7 Change the steering cylinder Lift aside the steering cylinder NOTE The steering cylinder is heavy use lifting equipment 8 Support the ne...

Страница 176: ...age Steering axle cradle general See section 6 Wheel suspension group 6 2 1 Steering axle cradle 5 2 6 Link arm page Link arm description 1 Link arm The link arm transfers the lateral movement of the...

Страница 177: ...2 9 Shuttle valve 13 5 2 9 Shuttle valve page Shuttle valve description See section 10 Common hydraulics group 10 5 3 Shuttle valve 5 2 13 Pipes and hoses page Piped and hoses description See section...

Страница 178: ...VDCF03 01GB Workshop Manual DCF 90 100 14 5 Steering 5 2 13 Pipes and hoses...

Страница 179: ...1 6 Suspension mm mm mm mm mm mm Table of Contents 6 Suspension 6 Suspension 3 6 2 Suspension 3 6 2 1 Steering axle cradle 4 6 2 2 Wheel spindle 6 6 2 3 Wheel hub 8 6 3 Tyre and rim system 13 6 3 1 Ty...

Страница 180: ...VDCF03 01GB Workshop Manual DCF 90 100 2 6Suspension...

Страница 181: ...ring axle s mounts are relieved NOTE Do not lift so much that the wheels are off the ground The illustration shows rear mounting 5 Remove the shafts holding the steering axle 6 Lift the machine so tha...

Страница 182: ...fting equipment from the machine 6 2 1 Steering axle cradle page Steering axle cradle description Steering axle 1 Wheel hub 2 Wheel spindle 3 Link arm 4 Steering axle cradle 5 Steering cylinder 6 King...

Страница 183: ...unions at once to protect the hydraulic system from contamination 9 Remove the shafts holding the steering axle 10 Lift the machine up so that the frame is lifted away from the axle 11 Lift out the s...

Страница 184: ...ring axle and wheel hubs which means that the wheels can be turned page King pin bearing replacement 1 Machine in service position see section B Safety 2 Lift the machine under the steering axle at th...

Страница 185: ...so as not to damage the bearing race 15 Refit the three screws on the top of the steering axle cradle 16 Fit upper bearing s inner bearing race seal ring guard ring and seal ring as well as the lower...

Страница 186: ...Check also that the machine feels stable when driving straight ahead 6 2 3 Wheel hub page Wheel hub description 1 Wheel hub 2 Wheel bolt 3 Wheel nut 4 Hub cap 5 Spacer 6 Nut 7 Washer 8 Bearing 9 Bolt...

Страница 187: ...b with a lifting strap Route the lift sling over the hub and around a wheel bolt Install a clamp and nut to secure the lift sling Use manual forklift pallet forks or similar to lift the hub 7 Bend up...

Страница 188: ...rease EP2 15 Fit new bearing races in the hub Use a drift and press in the bearing races Never use directly on the bearings NOTE Fit the outer bearings with the larger diameter outward 16 Fit a new se...

Страница 189: ...k in the bearing with grease and fit the bearing Fit the washer and hub nut with the smooth surface in towards the hub 21 Remove the lifting equipment 22 Torque the bearing nut as follows A Lubricate...

Страница 190: ...he locking washer in the closest groove Lock the bearing nut and lock nut with the locking washer 25 Fill the bearing casing with grease and fit it 26 Grease the wheel bearing with grease through the...

Страница 191: ...lease air through the valve if the tyre or rim is damaged Drill a hole in the tread to release the air Damaged tyres may explode Never stand directly in front of the wheel when deflat ing or inflating...

Страница 192: ...ive wheels ensure that the clamps clamp straight on the spacer ring Wheel nuts should be check tightened after 4 5 oper ating hours Always follow the tyre manufacturer s or other ap proved instruction...

Страница 193: ...s rolling circumference differs the stresses on the drive axle increase For this reason it is important that the tyres on the drive axle have equal wear and correct air pressure Spare and exchange tyr...

Страница 194: ...ms 6 3 2 Rims page Rim description 1 Rims 2 Lock ring 3 Rim flange 4 Rim bead seat taper 5 Wheel nut 6 Wheel bolt The rim is split to make it possible to fit a tyre the rim consists of the following p...

Страница 195: ...lamp 17 6 3 3 Nut washer and clamp page Nut washer and clamp description 1 Rims 2 Lock ring 3 Rim flange 4 Rim bead seat taper 5 Wheel nut 6 Wheel bolt The rim is attached to the wheel hub with nuts A...

Страница 196: ...d clamp page Wheel bolt replacing 1 Machine in service position see section B Safety 2 Raise the machine with a jack positioned under the steering axle 3 Remove the steering wheel see Maintenance manu...

Страница 197: ...ft cylinder 17 7 2 9 Mast 19 7 2 10 Mast position sensor 28 7 2 11 Lifting carriage 29 7 2 12 Valve block quick lift 33 7 2 13 Pipes and hoses 33 7 4 Side shift 34 7 4 1 Hydraulic oil pump 36 7 4 2 Co...

Страница 198: ...7 8 Mast 64 7 7 9 Pipes and hoses 64 7 8 Levelling 65 7 8 1 Hydraulic oil pump 67 7 8 2 Control valve attachment 67 7 8 3 Levelling cylinder 68 7 8 4 Lifting carriage 68 7 8 5 Valve block main pump r...

Страница 199: ...stlock B7203L and B7203R see Alignment sensor checking and adjusting page 77 Lifting hook B7203LL B7203LU 2 B7203RL and B7203RU 2 see Alignment sensor checking and adjusting page 90 4 Sensor locked tw...

Страница 200: ...nsor adjusting Adjusting position sensor indicator 1 Machine in service position see section B Safety 2 Check that the sensor in question is free of damage and dirt 3 Check that the distance between t...

Страница 201: ...wards LOWER push the lever forwards The lowering speed can only be varied through lever movement engine speed has no impact b Tilt R8072 P2 IN pull the lever backwards OUT push the lever forwards c Si...

Страница 202: ...witch is pressed at position 4 spreading in is activated See Spreading function description page 43 The signal can be checked from the diagnostic menu see section 8 Control system group 8 4 9 3 ATTACH...

Страница 203: ...Twistlocks are opened with the switch on the control lever see Control levers for electric servo description page 5 The switch is supplied power by and sends a voltage signal to the cab control unit D...

Страница 204: ...automatic spreading between 20 and 40 S1004 When the switch is depressed spreading automatically goes to the next position 20 30 or 40 feet if spreading is activated with the con trol lever This swit...

Страница 205: ...ues Locked or unlocked not inter mediate position Twistlocks description page 69 or Lifting hook description page 80 Alignment Mast down no contact Sensor alignment description page 77 or Alignment an...

Страница 206: ...r request via the CAN bus Checked by control system error shown with error code Section 11 Common electrics group 11 5 3 1 Cab control unit D790 1 3 The frame control unit D797 1 sends current proport...

Страница 207: ...ick lift The hydraulic pressure sensor left lift cylinder B768 L1 sends the frame con trol unit D797 1 a voltage signal pro portional to oil pressure UB768 L1 1 5 V UB768 L1 2 0 V UB768 L1 5 0 5 4 5 V...

Страница 208: ...great the insert is pressed down so that the oil passes by the insert This occurs if the oil is viscous cold or incorrect viscosity or if the filter insert is clogged 20 Lift speed increases Lift cyli...

Страница 209: ...d together with the servo pressure accumulator Servo pressure is stored in an accumulator for quicker start up and for emergency reduction of load An integrated non return valve prevents pressure leak...

Страница 210: ...sting screw to be seen on the pressure gauge Sometimes the engine has to be shut off between the checks Clockwise reduce pressure Counter clockwise increase pressure 7 Depressurize the hydraulic syste...

Страница 211: ...cessary 7 2 5 Control valve lift and tilt page Control valve lift and tilt description 009915 2 1 14 10 9 3 4 5 12 11 7 8 6 13 1 Solenoid valve lift Y6005 8 Connection rod side right lift cylinder B1...

Страница 212: ...the servo pressure The servo pressure acts on the spring centred control spool in the control valve for the function in question and thereby controls the main flow The speed of the function is control...

Страница 213: ...ted in parallel and fed from lift and tilt con trol valve see Control valve lift and tilt description page 15 page Hydraulic cylinders repairs See section 10 Common hydraulics group 10 7 1 Hydraulic c...

Страница 214: ...he O rings are intact and fitted correctly 6 Connect the wiring to the hydraulic pressure sensor 7 Clamp the cable harness as before 8 Turn on the main electric power and start the engine 9 Activate l...

Страница 215: ...lowered by the lift cylinders Mast wheels and slide plates between the inner and outer masts guide the inner mast in the outer mast and reduce friction between the two parts of the mast The lower part...

Страница 216: ...vate the hydraulic functions to depressurise the hydraulic system 7 Turn the start key to position 0 and turn off the main electric pow er 8 Mark up and disconnect the hydraulic connections of the lif...

Страница 217: ...ylinder from the mast Remove the cylinder shaft If necessary use the threaded hole and a puller to press the shaft out Start the engine and retract the cylinder so that it comes loose from the mountin...

Страница 218: ...elease the mast from the chassis 16 Lift aside the mast 17 Place the mast on the ground and detach the lifting equipment overhead crane 009983 WARNING The mast can swing out when it is released from t...

Страница 219: ...s installed check shafts and bearing surfaces for deep cracks or scratches and check that the bearings have no fi bres that shoot out from the surface If the shaft bearing shows sign of damage it must...

Страница 220: ...ydraulic functions to depressurise the hydraulic system 12 Turn the start key to position 0 and turn off the main electric pow er 13 Lift the tilt cylinders with lifting equipment overhead crane and a...

Страница 221: ...talling page 30 22 Fit the side lifting attachment see Side lifting attachment install ing page 56 page Flanges on outer and inner mast beam Flanges on outer and inner mast beam description The mast a...

Страница 222: ...flange If the measurement exceeds 252 mm for a beam that is supposed to be 250 mm contact Kalmar Industries 7 Apply a thin layer of slide grease to the sliding surfaces of the out er mast and reassemb...

Страница 223: ...lates in outer mast adjusting NOTE If the slide plate extends less than 3 mm from the holder replace it 1 Lubricate the outer sliding surfaces of the inner mast with a thin layer of slide grease 2 Low...

Страница 224: ...ere is clearance between the mast wheel and the mast beam 4 Lock the clamping screw with the spring pin 7 2 10 Mast position sensor page Mast position sensor description The mast position sensor B7211...

Страница 225: ...ctive levelling the attachment can be levelled 3 The lifting carriage also houses the control valve for the hydraulic func tions of the lifting carriage and side lifting attachment See also Side shift...

Страница 226: ...re vent damage to the cylinders 12 Undo the lifting equipment travelling crane page Lifting carriage installing NOTE Read the safety instructions for oil before working see section B Safety 1 Park the...

Страница 227: ...ct the lifting carriage cable Grease the connectors with contact grease and join them up Fasten the wiring with the lock plate 10 Fit the side lifting attachment see Side lifting attachment install in...

Страница 228: ...justment to the clearance between the lifting carriage and inner mast is possible without removing the lifting carriage 2 If the slide plate extends less than 3 mm from the holder replace it 3 Use a g...

Страница 229: ...he sliding surfaces page Mast wheel adjusting For mast wheel adjustment see Mast wheel adjusting page 28 7 2 12 Valve block quick lift page Valve block quick lift description Valve block quick lift Th...

Страница 230: ...D3 Pos Explanation Signal description Reference 1a The side shift control lever R8073 P3 sends the cab control unit D790 1 a voltage signal proportional to le ver movement U 0 5 4 5 V Left U 2 5 V Rig...

Страница 231: ...n stant pressure to the hydraulic oil pump for load handling This serves as a load signal Valve block main pump relief description page 42 5 The attachment shuttle valve sends the load signal on to th...

Страница 232: ...ylinders push in the main beam sideways in relation to the lifting carriage Side shift cylinder description page 40 Pos Explanation Signal description Reference 009936 1 2 4 5 7 8 10 11 13 14 3 6 9 12...

Страница 233: ...e number of hoses to the valve The control valve has the following sections Levelling Spreading right extension beam Spreading left extension beam Twistlocks lock tongues Side shift Side shift spool T...

Страница 234: ...hoses from the control valve NOTE Plug all connections immediately to protect the hydraulic system from impurities 4 Mark up and detach the wiring from the control valve 5 Remove the attaching bolts...

Страница 235: ...fety Operating menu hydraulic oil temperature 1 Operate and warm up the machine so that the hydraulic oil is at operating temperature at least 50 C As an alternative operate until the cooling fan is a...

Страница 236: ...ap on the measuring outlet 7 4 3 Side shift cylinder page Side shift cylinder description 1 Side shift cylinder The side shift cylinder sits between the lifting carriage and the side lift ing attachme...

Страница 237: ...the guide plate s guide pin 6 Pull out the glide plate with spacer plate and bracket 7 Measure the thickness of the slide plate Replace if necessary NOTE The thickness should be at least 10 mm 8 Place...

Страница 238: ...he hydraulic oil pump does not become too high When the solenoid valve is not activated the load signal is drained to the tank and the inlet from the control valve s supply is closed The valve is regu...

Страница 239: ...D15 D16 D9 D8 D3 Pos Explanation Signal description Reference 1a The switch for spreading 20 40 S1012 sends a voltage signal to the cab control unit D790 1 U 24 V Switch spreading 20 40 description p...

Страница 240: ...preading out left Y6018L or the solenoid valve for spreading in left Y6019L I 350 600 mA Section 11 Common electrics group 11 5 3 5 Attachment control unit D791 1 D8 Diagnostic menu see section 8 Cont...

Страница 241: ...group 8 4 9 17 ATTACH menu 17 and 8 4 9 18 ATTACH menu 18 18 The attachment control unit D791 1 reduces the control current to the solenoid valve for spreading out right Y6018R or the solenoid valve f...

Страница 242: ...or stop at 30 S1004 sends a voltage signal to the cab con trol unit D790 1 Switch in on position Conn 1 U 0 V Conn 5 U 24 V Switch in off position Conn 1 U 24 V Conn 5 U 24 V Switch stop at 30 descrip...

Страница 243: ...ntrol system group 8 4 9 6 ATTACH menu 6 7 The attachment control unit D791 1 dampens the speed the same way as in steps 17 22 of normal spreading Spreading function description page 43 8 When the lef...

Страница 244: ...ignal description Reference 1a The switch for spreading 20 40 S1012 sends a voltage signal to the cab control unit D790 1 U 24 V DC Switch spreading 20 40 description page 7 D2 Diagnostic menu see sec...

Страница 245: ...sensor for 20 40 end po sition left B769L sends a voltage signal to the attachment control unit D791 1 which activates damping for the left spreader beam the same way as in steps 16 22 of normal sprea...

Страница 246: ...cuts off the current to the solenoid valve for spreading out left Y6018L or the solenoid valve for spreading in left Y6019L I 0 mA Section 11 Common electrics group 11 5 3 5 Attachment control unit D...

Страница 247: ...e servo valve is controlled electrically by the solenoid valve for spreading in left Y6019L or the solenoid valve for spreading in right Y6019R which are activated by the attachment control unit D791...

Страница 248: ...slide plates 3 Take the strain off the glide plate in question The pressure can be relieved from the slide plates by raising the outer edge of the spreader beam or inserting wedges to alter the posit...

Страница 249: ...ide lifting attachment page Side lifting attachment s main beam description Main beam The side lifting attachment s main beam is fastened in the lifting car riage with hydraulic cylinders The main bea...

Страница 250: ...sed the threaded hole and a puller to press out the shaft Start the engine and retract the cylinder so that it comes loose from the mounting in the lifting carriage Switch off the engine Save the circ...

Страница 251: ...rotect the terminals by greasing them with contact grease Then loosely insert the connectors Remove the cable harness clamping ring 12 Detach the front panels upper mounting in the lifting carriage Us...

Страница 252: ...osition 3 Stop the engine 4 Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system 5 Turn the start key to position 0 and turn off the main electric...

Страница 253: ...let If necessary detach the hydraulic connections on the side shift cylinder to make it possible to adjust cylinder length 11 Attach the cable harness of the attachment to the attachment control unit...

Страница 254: ...30 foot stop option two extra sensors are mounting sensor for end position 30 B777R and B777L along with two additional in dicator plates The sensor is used to activate the 30 foot stop The sensors ar...

Страница 255: ...VDCF03 01GB Workshop Manual DCF 90 100 7 Load handling 7 5 8 Pipes and hoses 59 7 5 8 Pipes and hoses page Piped and hoses description See section 10 Common hydraulics group 10 5 1 Pipes and hoses...

Страница 256: ...See pressure plate on left frame beam Section 10 Common hydraulics group 10 4 2 Axial piston pump with variable displacement 2 The pressure reducer reduces the pres sure from one of the hydraulic pum...

Страница 257: ...ever description page 6 D5 Diagnostic menu see section 8 Control system group 8 4 8 1 ELSERV menu 1 6 The cab control unit D790 1 transmits tilt in or tilt out on the CAN bus Checked by control sys te...

Страница 258: ...e tilt spool is pressurised and controls the direction and flow of oil from the hydraulic oil pumps to the tilt cylinders Solenoid valve tilt out On machines with electric servo the solenoid valve for...

Страница 259: ...ts the tilt cylinders from moving faster than the pressure applied from the load handling control valve This prevents unwanted tilting forwards which can occur if there is a heavy load or high lift he...

Страница 260: ...ulic cylinders repairs See section 10 Common hydraulics group 10 7 1 Hydraulic cylinders 7 7 8 Mast page Lift masts description See Lift masts description page 19 7 7 9 Pipes and hoses page Piped and...

Страница 261: ...of the container to be lifted page Active levelling function description Condition Reference value Reference Emergency stop switch Not activated Section 11 Common electrics group 11 5 1 4 Emergency st...

Страница 262: ...il pump for load handling or the cab tilt shuttle valve Section 10 Common hydraulics group 10 5 3 Shuttle valve 6 The cab tilt shuttle valve sends the load signal on to the hydraulic oil pump for load...

Страница 263: ...r levelling right controls pressure to the levelling spool so that it opens and pressurises the levelling cylinders The solenoid valve for levelling right is regulated electrically by the so lenoid va...

Страница 264: ...ng attachment in relation to the machine page Hydraulic cylinders repairs See section 10 Common hydraulics group 10 7 1 Hydraulic cylinders 7 8 4 Lifting carriage page Lifting carriage description Se...

Страница 265: ...h side side of the side lifting attachment detect the position of the linkage and indicate whether the twistlocks are open or locked The status of the twistlocks is shown by indicator lights on the si...

Страница 266: ...iption page 75 Section 8 Control system group 8 2 2 Bypassing 009365 D790 1 D797 1 D791 1 8 10 9 2b 2a 13 18 18 17 16 15 3 3 7 22 4 6 14 21 P1 T1 A B 1 D790 2 D795 D1 D2 D9 D10 19 19 5 23 20 D6 11 12...

Страница 267: ...p 11 5 3 5 Attachment control unit D791 1 5 The KID control unit D795 activates the alignment event menu Section 11 Common electrics group 11 5 3 12 KID control unit D795 6 The attachment control modu...

Страница 268: ...e Control valve attachment description page 36 17 The overcentre valve prevents the un controlled opening or closing of the twistlocks 18 The lock cylinders rotate the twistlocks Lock cylinder descrip...

Страница 269: ...k spool so that the spool opens and pressurises the lock cylinders The lock twistlocks solenoid valve is regulated electrically with the lock twistlocks solenoid valve Y6040 which is activated by the...

Страница 270: ...e valve sits to the left of the attachment control valve on the lifting carriage 7 9 1 4 Lock cylinder page Lock cylinder description The lock cylinder pulls the lock mechanism so that the twistlocks...

Страница 271: ...ocking 2 Unlocked twistlock sensor 3 Sensor alignment 4 Locked twistlock sensor 5 Lift pin 6 Alignment pin Twistlocks secure the load and are located in the corners of the spreader beam s longitudinal...

Страница 272: ...oving the clamp halves 6 Remove the clamp halves and lift away the twistlock 7 Fit a new twistlock and secure it with the clamp halves NOTE Remember the washer 8 Check the positions of the parts and t...

Страница 273: ...attachment is lifted The sensors are supplied power and send a 24 V signal to the attach ment control unit D791 1 when the indicator pin is pressed in The signal can be checked from the diagnostic me...

Страница 274: ...f the lock mechanism Both sides function the same way independently of one another An indicator plate sits on the lock mechanism at the lock cylinder When the lock mechanism is in the position that lo...

Страница 275: ...at the twistlocks open indicator light is lit 4 Lower the attachment over a container and lock the twistlocks 5 Check that the LED on the locked twistlock sensor is lit If necessary slacken the lock n...

Страница 276: ...losed Indicator lights on the side lifting attachment and in the cab show the status of the lock tongues The lock tongues are activated manually or automatically and can be opened if the machine is dr...

Страница 277: ...description page 89 Section 8 Control system group 8 2 2 Bypassing 009959 D790 1 D797 1 D791 1 9 11 10 2b 2a 14 19 19 18 17 16 3 3 4 4 8 23 5 7 15 22 P1 T1 A B 1 D790 2 D795 20 21 6 C D2 D1 D20 D10 D1...

Страница 278: ...detection sensor description page 90 D3 Diagnostic menu see section 8 Control system group 8 4 9 23 ATTACH menu 23 4 The sensor for upper container right de tection B7203RU and the sensor for upper c...

Страница 279: ...t 15 The attachment control unit D791 1 activates the open lock tongue sole noid valve Y6039 or the lock lock tongue solenoid valve Y6040 U 24 V Section 11 Common electrics group 11 5 3 5 Attachment c...

Страница 280: ...stic menu see section 8 Control system group 8 4 9 10 ATTACH menu 10 22 The attachment control unit D791 1 transmits lock tongues unlocked or lock tongues locked on the CAN bus Checked by control sys...

Страница 281: ...sure to the lock tongue spool so that the spool opens and pressurises the lock cylinders The valve spool is regulated electrically by the lock lock tongues so lenoid valve Y6040 which is activated by...

Страница 282: ...trolled opening or closing of the lock tongues There is one non return valve at each lock cylinder on the side lifting attachment 7 9 2 4 Lock cylinder page Lock cylinder description The lock cylinder...

Страница 283: ...R 4 Alignment pin for alignment sensor lower container B7203LL RL 5 Lifting hook 6 Alignment pin for alignment sensor upper container B7203LU 2 RU 2 6 Detection sensor upper container B7203LU RU The...

Страница 284: ...lock tongue 8 Fit a new lock tongue Apply lubricating grease to the shaft bolt 9 Fit the shaft bolt with a new lock nut 10 Fit the screw of the lock cylinder s mounting in the lock tongue NOTE Use a n...

Страница 285: ...The lifting hooks are marked with serial number page Lifting hook replacing 1 Machine in service position see section B Safety 2 Depressurize the hydraulic systems See section B Safety 3 Clean the li...

Страница 286: ...ignment sensors sense the position of a spring pin which is pressed in when the attachment has contact up against the container The sensor is located behind the pin The position of the sensor can be a...

Страница 287: ...ound to detect whether one or two containers will be handled The sensors are acti vated when the attachment is 30 50 cm from the container At that time the alignment event menu lights up on the displa...

Страница 288: ...it D791 1 when the indicator plate is in front of the sensor The signal can be checked from the diagnostic menu see section 8 Control system group 8 4 9 8 ATTACH menu 8 page Lock tongue sensor checkin...

Страница 289: ...hen alignment disappears with locked twistlocks lock tongue and the twistlocks lock tongue are not reopened within eight seconds page Container counter function description Condition Reference value R...

Страница 290: ...send a voltage signal to the attachment control unit D791 1 Sensor directly opposite indicator plate U 24 V Sensor twistlocks description page 78 or Lock tongue sensor description page 92 D5 Diagnost...

Страница 291: ...Container counter 95 10 If the twistlocks lock tongue remains locked for 8 seconds the cab control unit D790 1 adds one lift to the con tainer counter Section 11 Common electrics group 11 5 3 1 Cab co...

Страница 292: ...VDCF03 01GB Workshop Manual DCF 90 100 96 7 Load handling 7 10 1 Container counter...

Страница 293: ...7 8 2 2 Bypass 7 8 2 3 Speed limitation 7 8 2 4 Service indicator 8 8 4 Diagnostics 9 8 4 1 CAN POWER 11 8 4 2 LIGHTS 26 8 4 3 CAB 37 8 4 4 CLIMATE 45 8 4 5 HYD 51 8 4 6 ENGINE 58 8 4 7 TRANSM 65 8 4...

Страница 294: ...VDCF03 01GB Workshop Manual DCF 90 100 2 8 Control system...

Страница 295: ...ol system function is divided into the following functions Monitoring Error codes Diagnostics Settings Software Monitoring functions describes the machine s monitoring functions that warn the operator...

Страница 296: ...hat 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 The error code is shown automat...

Страница 297: ...n with error code number XX YY on display Field D Type of error 1 Too high too low temperature 2 Incorrect signal to solenoid valve 3 Incorrect hydraulic pressure 4 Incorrect sensor signal 5 Incorrect...

Страница 298: ...up down 8 Tilt forks 9 Side shift forks 10 Spreading forks 11 Rotation forks 12 Overload protection 13 Hydraulic functions 14 Brake system 15 Steering 16 Engine 17 Transmission 18 Central lubrication...

Страница 299: ...put signal to solenoid valves with active error codes engagement of a gear without the operator in the driver s seat the machine can only move at reduced speed 8 2 3 Speed limitation page Speed limita...

Страница 300: ...ndicator reset Code is obtained from Kalmar Industries Support NOTE The code determines which service menu shall be activated Service Diagnostics Initiation or Calibration 4 Reset the service indicato...

Страница 301: ...cription page 26 Cab functions CAB description page 37 Air conditioning CLIMATE description page 45 Hydraulic functions HYD description page 51 Engine ENGINE description page 58 Transmission TRANSM de...

Страница 302: ...26 CAB description page 37 CLIMATE description page 45 HYD description page 51 ENGINE description page 58 TRANSM description page 65 ELSERV description page 76 ATTACH description page 90 OLS descript...

Страница 303: ...0 where 1 means closed circuit OUTPUT two characters where the first number is 1 if the output signal is active The second number is status for the circuit 1 circuit OK 0 open circuit or short circuit...

Страница 304: ...where the first open circuit is If there is open cir cuit it is indicated with a number that corresponds to the incorrect seg ment on the redundant CAN bus Circuit diagram Circuit 11 6 1 Connection F...

Страница 305: ...1 Connection Function 11 6 2 Redundant CAN bus Signal value 8 4 1 4 CAN POWER menu 4 page PRESENT DRIVE TRAIN CAN BUS STATUS ENGINE Description Indicates status for engine in drivetrain s CAN bus Circ...

Страница 306: ...RESENT DRIVE TRAIN CAN BUS STATUS TRANSMISSION Description Indicates status for transmission in drivetrain s CAN bus Circuit diagram Transmission circuit group 2 0 CAN bus circuit group 11 6 Connectio...

Страница 307: ...uit 11 5 3 Connection output signal from D790 1 K10 16 to K315 2 Function 11 5 1 3 Ignition voltage 15 Signal value IGNITION KEY IN RELAY K315 1 RELAY K315 2 X XY XY DIAG CAN POWER 5 X 007126 1 Input...

Страница 308: ...K3009 1 indicates that relay is working normally Circuit diagram sheet 11 5 6 Connection signal from K3009 1 87 via F58 3 8 to digital in D790 1 K11 13 Function 11 5 1 4 Control switch voltage 15E Si...

Страница 309: ...90 1 K4 5 to Y672 10 and Y673 10 2 signal from digital out D790 1 K5 11 to S118 1 S 139 1 and S117 1 3 signal from digital out D790 1 K5 13 till B690 1 1 and B690 2 1 4 signal from digital out D790 1...

Страница 310: ...rom digital out D790 1 K7 12 not connected 5 signal from digital out D790 1 K8 16 to S107 5 S169 3 S199 2 5 S250 1 S1002 2 S1003 3 S1004 5 S1005 5 S1010 3 S1012 3 S1037 5 6 signal from digital out D79...

Страница 311: ...undant 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 01 No output signal Error detection only possible when output signal is a...

Страница 312: ...of control units Signal value page 797 1 FRAME POWER 2 Description Battery voltage to frame control unit D797 1 Circuit diagram Circuit 11 5 4 Connection 15 voltage from K315 1 87 via F54 4 and F58 2...

Страница 313: ...22 30 V battery voltage page 793 TRANSMISSION SENSOR SUPPLY Description Voltage feed to sensors on transmission reference volt age of 5 V Circuit diagram Circuits 2 0 2A2 2 0 2A3 Connection 5V analogu...

Страница 314: ...797 2 K2 7 Ri redundant feed to D797 2 K2 8 Function 11 5 1 2 Redundant voltage feed of control units Signal value page 797 2 FRAME OPT EME STOP POWER Description Emergency stop switch voltage to fram...

Страница 315: ...uit diagram Circuit 11 5 5 Connection 15E voltage from K3009 1 87 via K3009 2 87 F58 3 1 to D791 1 K2 1 K2 9 K2 10 K2 11 Function 11 5 1 4 Control switch voltage 15E Signal value XX XXV voltage on the...

Страница 316: ...ndant 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 page 791 1 FRAME EME POWER 2 Description Emergency stop sw...

Страница 317: ...5R Function 7 5 6 Spreading position sensor 7 9 1 7 Alignment position sensor 7 9 1 8 Twistlocks sensor DCF 90 100 with lifting hook Connection digital out from 791 1 K1 10 to B769L B769R B777L B777R...

Страница 318: ...50CSG Segment numbering with maximum number of control units Control units marked with dashes are optional Circuit diagram Circuit CAN bus group 11 6 Connection Function 11 6 2 Redundant CAN bus Signa...

Страница 319: ...l out from D797 1 K1 33 to H412L and H412R Function 9 6 3 Rear lights Signal value MAIN LIGHT SWITCH X DIAG LIGHTS 1 X 005286 1 Input signal active 0 No signal PRESENT OUTPUT SIGNAL SIDE LIGHTS REAR L...

Страница 320: ...om D797 1 K1 28 to E400L and E400R Function 9 6 1 Headlights Signal value HEAD LIGHTS SWITCH HEAD LE RI DIMMED LE RI X XY XY DIAG LIGHTS 3 X 005288 1 Input signal active 0 No signal 00 No output signa...

Страница 321: ...OUTPUT SIGNAL HAZARD FLASHER LEFT F R Description Voltage feed to direction indicator left hand side Circuit diagram Circuit 9 6 7 Connection digital out from D797 1 K1 30 to H422 and H426 Function 9...

Страница 322: ...lue page ROTATING BEACON OUTPUT Description Voltage feed to rotating beacon Circuit diagram Circuit 9 6 4 Connection digital out from D790 1 K2 5 to H428 Function 9 6 8 Rotating beacon Signal value 00...

Страница 323: ...e feed to brake lights Circuit diagram Circuit 9 6 6 Connection LE digital out from D797 1 K1 7 to H411L RI digital out from D797 1 K1 9 to H411R Function 9 6 4 Brake lights Signal value PRESENT INPUT...

Страница 324: ...onnection signal from D790 2 K8 11 to digital in D790 1 K11 2 Function 9 6 Lighting system Signal value 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting S...

Страница 325: ...cab Circuit diagram Circuit 9 6 8 Connection digital out from D790 1 K11 6 to E434 1 Function 9 6 11 Interior lighting Signal value XXX 0 255 0 24 V 255 means 24 V which corre sponds to battery voltag...

Страница 326: ...t attachment 9 1 6 Switch for working light mast Signal value 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting can only be detected when...

Страница 327: ...9 6 1 Connection 20 digital out from D790 1 K7 8 to E406L 2 and E406R 2 40 digital out from D790 1 K10 8 to E406L 1 and E406R 1 Function 9 6 10 Work light cab Signal value 00 No output signal open ci...

Страница 328: ...ls and keys Circuit diagram Circuits 4 0 1 5 2 1 7 5 1 7 9 1 9 1 1 9 3 1 9 3 3 9 4 1 9 6 2 9 6 3 9 6 4 9 6 1 Connection output signal from D790 1 K6 1 to S117 S118 S139 output signal from D790 1 K6 2...

Страница 329: ...ption Signal from entry lighting switch Circuit diagram Circuit 9 6 11 Connection signal from S141 2 to digital in D790 1 K11 4 Function 9 6 13 Entry lighting Signal value page STEP LIGHT OUTPUT Descr...

Страница 330: ...ng activation is controlled by controlling grounding of the motor The mo tor is grounded at windshield washing if the wiper motor roof or rear window is activated Circuit diagram Circuit 9 5 1 Connect...

Страница 331: ...ont Circuit diagram Circuit 9 5 1 Connection digital out from D790 1 K2 1 to M650 1 53 Function 9 5 5 Wiper motor front Signal value page FRONT WIPER FEEDBACK Description Signal from motor wiper front...

Страница 332: ...er motor rear Signal value page REAR WIPER FEEDBACK Description Signal from motor windshield wiper rear indicates when wiper motion is completed Circuit diagram Circuit 9 5 1 Connection signal from M6...

Страница 333: ...f indicates when wiper mo tion is completed Circuit diagram Circuit 9 5 1 Connection signal from M650 3 31B to digital in D790 1 K12 4 Function 9 5 6 Wiper motor roof Signal value ROOF WIPER SWITCH OU...

Страница 334: ...on signal from S149 3 to digital in D790 1 K9 10 Function 9 7 Signal system Signal value page HORN OUTPUT Description Voltage feed to horn Circuit diagram Circuits 9 7 1 and 9 7 3 Connection digital o...

Страница 335: ...ion Status for alarm indication panel warning from control system Circuit diagram Connection Function 8 1 2 Information display BUZZER SWITCH SEAT ALARM OP XY X X X DIAG CAB 6 X 005546 00 No output si...

Страница 336: ...nsor fuel level in ohm page FUEL PROC Description Control system s interpretation of signal from fuel tank sensor Circuit diagram Connection Function 1 2 2 Sensor fuel level Signal value XXX 0 100 0 1...

Страница 337: ...d adjusted in increments of half degrees 200 20 C Test by increasing or decreasing temperature with the temper ature switch on the panel page PRESENT INPUT SIGNAL PRESENT TEMP Description Signal from...

Страница 338: ...cool ant Signal is retrieved from the engine via CAN bus drivetrain Circuit diagram Circuits 9 4 1 9 4 2 Connection from engine via CAN bus see PRESENT INPUT SIG NAL COOLANT TEMP page 63 Function 1 7...

Страница 339: ...oltage is a measure of the valve s position Circuit diagram Circuit 9 4 2 Connection signal from Y672 9 to analogue in D790 1 K4 7 Function 9 4 14 Air distributor Signal value XX XXV 0 50 4 50 V 8 4 4...

Страница 340: ...ction signal from S118 3 to analogue in D790 1 K5 7 Function 9 4 Heating ventilation and climate control unit Signal value XX XXV 2 4 0 5 0 V Increase decrease 8 4 4 6 CLIMATE menu 6 page PRESENT OUTP...

Страница 341: ...reafter it may be difficult to determine if the valve is working as it should Circuit diagram Circuit 9 4 2 Connection digital out from D790 1 K4 1 via R3 to Y673 5 and from D790 1 K4 2 via R4 to Y673...

Страница 342: ...r rotation clock wise Is connected to an H bridge Signal can only be diagnosed when the air distributor s position changes Circuit diagram Circuit 9 4 2 Connection digital out from D790 1 K4 3 via R5...

Страница 343: ...m sensor hydraulic oil temperature Circuit diagram Circuit 10 6 1 Connection signal from B776 1 to temperature in D797 1 K2 13 Function 10 6 4 Sensor hydraulic oil temperature Signal value XXX Tempera...

Страница 344: ...raulic oil temperature sensor Signal value XXX Temperature in tenths of degrees 200 20 C page BRAKE COOLANT OIL FAN Description Voltage feed to cooling fan brake oil Circuit diagram Circuit 4 8 1 Conn...

Страница 345: ...gnal value XXX 0 250 Hydraulic pressure 0 25 MPa 255 incorrect signal page HYDRAULIC PRESSURE TILT CYLINDER Description Pressure on the tilt cylinders rod side C For voltage value see PRESENT INPUT SI...

Страница 346: ...contact brake lights Circuit diagram Circuit 9 6 5 Connection signal from S216 2 to digital in D797 1 K1 20 Function 4 3 8 Make contact brake lights Signal value page PRESSURE SWITCHES DECLUTCH PRESSU...

Страница 347: ...0 to analogue in D797 1 K1 41 Function 4 5 5 Normally open NO switch parking brake Signal value page P BRAKE VALVE Description Voltage feed to Solenoid valve parking brake Circuit diagram Circuit 4 0...

Страница 348: ...e Y6062 2 Function 10 4 2 Axial piston pump with variable displacement Signal value CUT OFF HYDRAULIC PUMPS PUMP 2 PUMP ATTACHMENT XY XY DIAG HYDRAULIC 6 X 007242 00 No output signal open circuit in c...

Страница 349: ...noid valve Y6062 is activated or deactivated with Function 10 4 2 Axial piston pump with variable displacement Signal value 8 4 5 8 HYD menu 8 page PRESENT OUTPUT SIGNAL PRESSURE TO ATTACHM VALVE Only...

Страница 350: ...1 page PRESENT INPUT SIGNAL ACCELERATOR Description Signal from accelerator pedal Circuit diagram Circuit 1 0 1 Connection signal from B690 1 2 to analogue in D790 1 K6 11 Function 1 Engine Signal va...

Страница 351: ...Engine speed from transmission control unit D793 to the cab control unit D790 1 via the CAN bus drivetrain The actual value for engine speed Circuit diagram Connection Function 2 2 5 Sensor engine rpm...

Страница 352: ...ngine 1 10 1 Preheating Signal value page PRESENT INPUT SIGNAL CRANK ENGINE SWITCH Description Signal from ignition start position Circuit diagram Circuits 11 5 3 1 0 1 Connection signal from S150 50...

Страница 353: ...Start and stop Signal value page PRESENT OUTPUT SIGNAL CRANK ENGINE WIRE Description Voltage feed to starter motor relay For Cummins QSM11 Circuit diagram 1 0 1 1 0 2B1 Connection digital out D797 1 K...

Страница 354: ...nit D794 to cab control unit D790 1 Circuit diagram See supplier documentation engine Connection Volvo TAD760VE signal from 33 charge air pressure sensor to engine control unit D794 Connector A sleeve...

Страница 355: ...ontrol unit D794 Sensor connector sleeve 42 Function 1 8 7 Sensor oil temperature Signal value XXX 200 equals 20 C page PRESENT INPUT SIGNAL COOLANT TEMP Description Coolant temperature CAN bus messag...

Страница 356: ...R NO OF ACT ERROR Description Number of error codes from engine control unit EDC D794 Circuit diagram Connection Function 1 9 Control system Signal value XX number of active error codes page PRESENT E...

Страница 357: ...utch pedal Circuit diagram Circuit 2 0 1 Connection signal from S220 1 2 to digital in D790 1 K6 14 Function 2 Transmission Signal value page PRESENT INPUT SIGNAL DECLUTCH PRESS SW Description Signal...

Страница 358: ...onnection signal from S162 R to digital in D790 2 K3 12 Function 2 Transmission Signal value page SWITCHES SHIFT MODE Description Signal from shifting program switch Status on CAN bus from KIT control...

Страница 359: ...stem transmission Signal value page PRESENT VALUE GEAR Description Current gear status from transmission control unit D793 Shows which gear is activated in the transmission Circuit diagram Function 2...

Страница 360: ...5 TRANSM menu 5 page OPERATING STATE SHIFT IN PROGRESS Description Status for transmission function during operation shifting in progress Active during shifting Circuit diagram Connection Function 2...

Страница 361: ...Sensor drum rpm B752 2 Temperature monitor torque converter S221 3 Sensor engine rpm and temperature transmission B758 766 4 Sensor rpm turbine transmission B751 5 Sensor rpm output shaft B758 Descri...

Страница 362: ...m the sensor in Hz pulses second To convert to rpm divide frequency by number of teeth on input shaft s gear page TURBINE SPEED Description Signal from sensor rpm turbine transmission position 4 Circu...

Страница 363: ...trol system transmission Signal value 8 4 7 8 TRANSM menu 8 page FWD SUPPLY Description Status for control current to clutch pack forward Circuit diagram Circuit 2 0 2A3 Connection signal from D793 B1...

Страница 364: ...gnal value 8 4 7 9 TRANSM menu 9 page FWD FEEDBACK Description Present control current to solenoid valve clutch pack forward Circuit diagram Circuit 2 0 2A3 Connection signal from D793 B1 to Y630 Func...

Страница 365: ...tors in the cable harness to generate different voltage levels Circuit diagram Circuit 2 0 2A2 Connection signal from pressure feedback sensor to D793 A2 Function 2 6 2 Sensor oil pressure Signal val...

Страница 366: ...nction 2 8 Control system transmission Signal value XXXX Drive wheels radius in mm 8 4 7 12 TRANSM menu 12 page SPEED LIMIT CAB Description Speed limitation from D790 1 e g emergency stop switch activ...

Страница 367: ...own Circuit diagram Connection Function 2 8 Control system transmission Signal value XXX First part of error code see section D Error codes page TYPE Description Indicates type of active error Circuit...

Страница 368: ...rvo functions Confirm selection with function key for Enter 8 4 8 1 ELSERV menu 1 page PRESENT INPUT SIGNALS P1 Description Signal from control lever P1 Circuit diagram Circuits 7 0 1 7 0 2 Connection...

Страница 369: ...8074 3 S815 1 to analogue in D790 1 K7 6 Function 7 1 1 Control levers Signal value XX XXV 0 50 4 50 V 2 5 V in zero position page PRESENT INPUT SIGNALS P7 Description Signal from control lever P7 Cir...

Страница 370: ...Circuit 7 2 1 Connection output signal reference value out from D797 1 K1 16 to Y6005 2 Y6005 1 2 on machines with freelift Function 7 2 5 Control valve lift and tilt DCF360 450CSG and DCF 90 100 7 2...

Страница 371: ...Circuit 7 2 1 Connection output signal reference value out from D797 1 K1 17 to Y6004 2 Y6004 1 2 on machines with freelift Function 7 2 5 Control valve lift and tilt DCF360 450CSG and DCF 90 100 7 2...

Страница 372: ...ircuit diagram Circuit 7 7 1 Connection output signal reference value out from D797 1 K1 18 to Y6011 2 Function 7 7 5 Control valve lift and tilt DCF360 450CSG and DCF 90 100 7 7 5 Control valve load...

Страница 373: ...m Circuit 7 7 1 Connection output signal reference value out from D797 1 K1 19 to solenoid valve Y6010 1 Function 7 7 5 Control valve lift and tilt DCF360 450CSG and DCF 90 100 7 7 5 Control valve loa...

Страница 374: ...load handling solenoid valve side shift left Circuit diagram Circuit 7 4 1 Connection output signal reference value out from D797 2 K1 18 to Y6020 2 Function 7 4 5 Control valve load handling DCF280...

Страница 375: ...load handling solenoid valve side shift right Circuit diagram Circuit 7 4 1 Connection output signal reference value out from D797 2 K1 18 to Y6021 2 Function 7 4 5 Control valve load handling DCF280...

Страница 376: ...load handling solenoid valve spreading in Circuit diagram Circuit 7 5 1 Connection output signal reference value out from D797 2 K1 19 to Y6019 2 Function 7 5 5 Control valve load handling DCF280 330...

Страница 377: ...load handling solenoid valve spreading out Circuit diagram Circuit 7 5 1 Connection output signal reference value out from D797 2 K1 19 to Y6018 2 Function 7 5 5 Control valve load handling DCF280 33...

Страница 378: ...load handling solenoid valve lift carriage Circuit diagram Circuit 7 10 1 Connection output signal reference value out from D797 2 K1 17 to Y6022 2 Function 7 2 6 Control valve load handling DCF280 33...

Страница 379: ...oad handling solenoid valve lower carriage Circuit diagram Circuit 7 10 1 Connection output signal reference value out from D797 2 K1 17 to Y6023 2 Function 7 2 6 Control valve load handling DCF280 33...

Страница 380: ...SENT INPUT SIGNALS PISTOL Description Signals from control lever for pistol trigger Circuit diagram Circuit 7 0 2 Connection from S815 19 to digital in D790 1 K7 16 Function 7 1 1 Control lever Signal...

Страница 381: ...7 0 2 Connection signal from S815 17 to digital in D790 1 K8 1 Function 7 1 1 Control lever Signal value 8 4 8 15 ELSERV menu 15 page REGENERATION STATUS INPUT DAMPING Description Signal from position...

Страница 382: ...This group covers attachment functions Confirm selection with function key for Enter 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting ca...

Страница 383: ...unction 7 1 1 Control levers Signal value XX XXV 0 50 4 50 V 2 5 V in zero position page PRESENT INPUT SIGNALS P7 Description Signal from control lever P7 Circuit diagram Circuit 7 0 1 Connection sign...

Страница 384: ...trol lever Signal value page PRESENT INPUT SIGNALS AUTO 20 40 Description Signal from switch automatic spreading 20 40 Circuit diagram Circuit 7 5 3 Connection from S1012 2 1 to digital in D790 1 K8 1...

Страница 385: ...NPUT SIGNALS UNLOCK TWISTLOCK Description Signal from control lever to unlock twistlock Circuit diagram Circuits 7 9 1 7 0 2 Connection signal from S1002 1 S815 20 to digital in D790 1 K7 15 Function...

Страница 386: ...e PRESENT INPUT SIGNALS ALIGNMENT LE RI FRONT Description Signals from sensors alignment right front and left front Circuit diagram Circuit 7 9 2 Connection LE signal from B7202L C to digital in D791...

Страница 387: ...in D791 1 K1 24 Function 7 9 1 7 Sensor twistlock Signal value page PRESENT OUTPUT SIGNAL LE RI UNLOCKED TW Description Signals from sensors open twistlock right and left Circuit diagram Circuit 7 9...

Страница 388: ...carriage Circuit diagram Circuit 7 9 1 Connection digital out from D791 1 K1 29 to H563 1 PRESENT OUTPUT SIGNAL LOCK TW UNLOCK TW XY XY DIAG ATTACHMENT 9 X 005424 00 No output signal open circuit in...

Страница 389: ...ting Short circuiting can only be detected when the output signal is active 10 Output signal active short circuiting 11 Output signal active circuit OK or open circuit Open circuit can only be detecte...

Страница 390: ...tachment control valve for output signal side shift left Circuit diagram Circuit 7 4 2 Connection output signal reference value out from D791 1 K1 18 to Y6020 2 Function 7 4 2 Control valve attachment...

Страница 391: ...chment control valve for output signal side shift right Circuit diagram Circuit 7 4 2 Connection output signal reference value out from D791 1 K1 18 to Y6021 2 Function 7 4 2 Control valve attachment...

Страница 392: ...ment control valve for output signal spreading out 20 40 Circuit diagram Circuit 7 5 2 Connection output signal reference value out from D791 1 K1 19 to Y6018 2 Function 7 5 2 Control valve attachment...

Страница 393: ...ment control valve for output signal spreading in 40 20 Circuit diagram Circuit 7 5 2 Connection output signal reference value out from D791 1 K1 19 to Y6019 2 Function 7 5 2 Control valve attachment...

Страница 394: ...Signal value PRESENT OUTPUT SIGNAL UNLOCK LEVELLING XY DIAG ATTACHMENT 15 X 005430 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting can...

Страница 395: ...output signal PWM off page OUTPUT PROJECT LE OUT REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal extension left side out Circuit diagram Ci...

Страница 396: ...following is also possible XY 01 No output signal PWM off page OUTPUT PROJECT LE IN REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal extens...

Страница 397: ...t control valve for output signal extension right side out Circuit diagram Circuit 7 3 1 Connection output signal reference value out from D791 1 K1 17 to Y6046 4 2 Function 7 3 2 Control valve attach...

Страница 398: ...nt control valve for output signal extension right side in Circuit diagram Circuit 7 3 1 Connection output signal reference value out from D791 1 K1 17 to Y6046 3 2 Function 7 3 2 Control valve attach...

Страница 399: ...2 Connection signal from R8073 3 S815 11 to analogue in D790 1 K7 5 Function 7 1 1 Control levers Signal value XX XXV 0 50 4 50 V 2 5 V in zero position page PRESENT INPUT SIGNALS P4 Description Sign...

Страница 400: ...TTACH menu 3 page PRESENT INPUT SIGNALS SPREADER Description Signals from switch for spreading the attachment Circuit diagram Circuits 7 5 1 7 0 2 Connection IN Signal from S1012 1 S815 14 to digital...

Страница 401: ...9 5 ATTACH menu 5 page PRESENT INPUT SIGNALS LOCK CONT Description Signal from switch lock lock tongue Circuit diagram Circuit 7 9 1 Connection signal from S1003 to digital in D790 1 K8 12 Function 7...

Страница 402: ...tion from inductive sensor B777L to digital in D791 K1 20 or from inductive sensor B777R to digital in D791 K1 37 Function 7 5 6 Position sensor spreading Signal value 8 4 9 7 ATTACH menu 7 page PRESE...

Страница 403: ...ked lock tongue right and left Circuit diagram Circuit 9 Connection LE signal from B7205LL to digital in D791 K1 23 RI Signal from B7205RL to digital in D791 K1 24 Function 7 9 2 9 Lock tongue sensor...

Страница 404: ...attachment Signal value PRESENT OUTPUT SIGNAL LOCK CONT UNLOCK CONT XY XY DIAG ATTACHMENT 9 X 010083 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting Shor...

Страница 405: ...ing hook Signal value PRESENT OUTPUT SIGNAL IND LOCKED CONT IND UNLOCKED CONT IND ALIGNMENT XY XY XY DIAG ATTACHMENT 10 X 010084 00 No output signal open circuit in circuit 01 No output signal circuit...

Страница 406: ...l PWM off page OUTPUT SIDE SHIFT LE REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal side shift left Circuit diagram Circuit 7 4 2 Connectio...

Страница 407: ...e following is also possible XY 01 No output signal PWM off page OUTPUT SIDE SHIFT RI REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal side...

Страница 408: ...o attachment control valve for output signal levelling right Circuit diagram Circuit 6 Connection output signal reference value out from D791 K1 19 to Y6035 Function 7 8 2 Control valve attachment Sig...

Страница 409: ...to attachment control valve for output signal levelling left Circuit diagram Circuit 6 Connection output signal reference value out from D791 K1 19 to Y6036 Function 7 8 2 Control valve attachment Sig...

Страница 410: ...he following is also possible XY 01 No output signal PWM off page OUTPUT SPREAD LE OUT REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal spre...

Страница 411: ...e following is also possible XY 01 No output signal PWM off page OUTPUT SPREADER LE IN REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal spre...

Страница 412: ...tachment control valve for output signal spreading right side out Circuit diagram Circuit 4 Connection output signal reference value out from D791 K1 17 to Y6018R Function 7 5 2 Control valve attachme...

Страница 413: ...ttachment control valve for output signal spreading right side in Circuit diagram Circuit 4 Connection output signal reference value out from D791 K1 17 to Y6019R Function 7 5 2 Control valve attachme...

Страница 414: ...Alignment and detection sensor Signal value 8 4 9 23 ATTACH menu 23 page PRESENT OUTPUT SIGNAL IND UPPER ALIGNMENT Description Signals from alignment sensor right upper B7203RU 2 and left upper B7203L...

Страница 415: ...l from R8074 3 S815 1 to analogue in D790 1 K7 6 Function 7 1 1 Control levers Signal value XX XXV 0 50 4 50 V 2 5 V in zero position page PRESENT INPUT SIGNALS P7 Description Signal from control leve...

Страница 416: ...ntrol lever Signal value page PRESENT INPUT SIGNALS AUTO 20 40 Description Signal from switch automatic spreading 20 40 Circuit diagram Circuit 7 5 3 Connection from S1012 2 1 to digital in D790 1 K8...

Страница 417: ...for locking twistlocks Circuit diagram Circuit 7 9 1 Connection signal from S1003 to digital in D790 1 K8 12 Function 7 9 1 Twistlocks Signal value page PRESENT INPUT SIGNALS UNLOCK CONT Description...

Страница 418: ...it diagram Circuit 5 Connection from inductive sensor B777L to digital in D791 K1 20 or from inductive sensor B777R to digital in D791 K1 37 Function 7 5 6 Position sensor spreading Signal value 8 4 9...

Страница 419: ...1 8 Twistlocks sensor Signal value 8 4 9 9 ATTACH menu 9 page PRESENT OUTPUT SIGNAL LOCK CONT Description Voltage feed to attachment control valve locked twist locks Circuit diagram Circuit 8 Connecti...

Страница 420: ...nlocked twistlocks lo cated on carriage Circuit diagram Circuit 10A Connection digital out from D791 K1 25 to H562 00 No output signal open circuit in circuit 01 No output signal circuit OK or short c...

Страница 421: ...s also possible XY 01 No output signal PWM off 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting can only be detected when the output sign...

Страница 422: ...4 9 12 ATTACH menu 12 page OUTPUT SIDE SHIFT RI REFERENCE Description Status for control current to attachment control valve for side shift right Circuit diagram Circuit 7 4 2 Connection digital out f...

Страница 423: ...ns the following is also possible XY 01 No output signal PWM off page OUTPUT LEVELLING CW REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal l...

Страница 424: ...to attachment control valve for output signal levelling left Circuit diagram Circuit 6 Connection output signal reference value out from D791 K1 19 to Y6036 Function 7 8 2 Control valve attachment Sig...

Страница 425: ...he following is also possible XY 01 No output signal PWM off page OUTPUT SPREAD LE OUT REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal spre...

Страница 426: ...e following is also possible XY 01 No output signal PWM off page OUTPUT SPREADER LE IN REQUIRED VALUE Description Reference value for control current to attachment control valve for output signal spre...

Страница 427: ...e value out from D791 K1 17 to Y6018R Function 7 5 2 Control valve attachment Signal value XXX Current value in mA for control of solenoid valve page OUTPUT SPREAD RI OUT FEEDBACK Description Present...

Страница 428: ...ge OUTPUT SPREADER RI IN FEEDBACK Description Present control current to attachment control valve for spreading right side in Circuit diagram Circuit 4 Connection output signal actual value out from D...

Страница 429: ...gnal from hydraulic pressure sensor lift cylinder C piston side See also HYDRAULIC PRESSURE TILT CYLINDER page 53 for pressure information Circuit diagram Circuit 8 2 2 Connection signal from B768 2 3...

Страница 430: ...lculated load Circuit diagram Connection Function 8 2 1 Overload protection Signal value XXXXX Weight kg page MAST POS SENSOR Applies to DCF360 450CSG with 14000 mm lift height Description Signal from...

Страница 431: ...ption This group covers reversible driver s seat functions Confirm selection with function key for Enter page VBFS menu 1 PRESENT INPUT SIGNAL REVERSIBLE SEAT SWITCH CW Description Signal from switch...

Страница 432: ...eed to seat reversal control unit clockwise rotation Circuit diagram Circuit 9 3 7 Connection digital out from D797 2 K1 29 to A798 6 Function 9 3 9 Reversible driver s seat Signal value 1 Input signa...

Страница 433: ...versible driver s seat Signal value PRESENT INPUT SIGNAL SEAT SENSORS SEAT POS REAR Description Signal from sensor reversible driver s seat rearward Circuit diagram Circuit 9 3 3 Connection signal fro...

Страница 434: ...engine speed in percent which is sent from the cab control unit D790 1 to the engine control unit D794 via the CAN bus drivetrain Circuit diagram Connection Function 1 9 Control system engine Signal v...

Страница 435: ...tion 9 3 12 Directional valve reversible driver s seat Signal value 005565 PRESENT OUTPUT SIGNAL STEERING VALVE VALVE CAB FRONT VALVE CAB REAR XY XY DIAG VBFS 5 X 00 No output signal open circuit in c...

Страница 436: ...ram Circuit 9 3 5 Connection digital out from D797 2 K1 1 to E402L 2 1 and E402R 2 1 Function 9 6 1 Headlights Signal value 005566 HEAD LIGHTS REAR SWITCH HEAD LE RI DIMMED LE RI X XY XY DIAG VBFS 6 X...

Страница 437: ...utput signal open circuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting can only be detected when the output signal is ac tive 10 Output signal active short circuiting...

Страница 438: ...unction 9 3 9 Reversible driver s seat 005568 PRESENT OUTPUT SIGNAL BRAKE LIGHT FRONT FRONT LE XY RI XY DIAG VBFS 8 X 00 No output signal open circuit in circuit 01 No output signal circuit OK or shor...

Страница 439: ...25 H1 to digital in D790 1 K9 8 Function 5 2 Power steering system Signal value XX XXV 0 50 4 50 V PRESENT INPUT SIGNAL SIGNAL 2 P7 Description Signal from mini wheel signal 2 Only applies to mini whe...

Страница 440: ...rcuit diagram Circuit 5 2 1 Connection signal from S113 1 to digital in D790 1 K9 5 Function 5 2 Power steering system Signal value SWITCHES FORWARD Description Signal from mini wheel or steering leve...

Страница 441: ...enu 4 OUTPUT STEERING LEFT REFERENCE Description Status for control current to control valve for mini wheel lever steering solenoid valve steering left Circuit diagram Circuit 5 2 2 Connection output...

Страница 442: ...NG menu 5 OUTPUT STEERING RIGHT REFERENCE Description Status for control current to control valve for mini wheel lever steering solenoid valve steering left Circuit diagram Circuit 5 2 2 Connection ou...

Страница 443: ...ge EXT ATTACH menu 1 PRESENT INPUT SIGNAL EXT ATTACH ACTIVE Description Signal which indicates if external attachment is connected Circuit diagram Circuit 7 0 4 Connection Function 7 10 5 Separate top...

Страница 444: ...r Signal value PRESENT INPUT SIGNALS SPREADING IN Description Signal from switch for spreading the attachment Circuit diagram Circuits 7 5 1 7 0 2 Connection signal from S1012 1 S815 14 to digital in...

Страница 445: ...page EXT ATTACH menu 5 PRESENT OUTPUT SIGNAL 4TH FUNCTION HYD 4TH OUT Description Voltage feed to 4th function out Circuit diagram Circuit 7 0 6 Connection digital out from D797 1 K1 36 to Y6039 6018...

Страница 446: ...ment Signal value 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting can only be detected when the output signal is ac tive 10 Output signa...

Страница 447: ...01 No output signal PWM off OUTPUT SPREADING IN REQUIRED VALUE Description Reference value for control current to load handling con trol valve solenoid valve spreading in Circuit diagram Circuit 7 5...

Страница 448: ...s the following is also possible XY 01 No output signal PWM off OUTPUT SPREADING OUT REQUIRED VALUE Description Reference value for control current to load handling con trol valve solenoid valve sprea...

Страница 449: ...al from B261 to digital in D797 1 K1 11 Function 7 2 10 Mast position sensor Signal value PRESENT INPUT SIGNAL MAST CARRIAGE LIFT CARRIAGE TOP Description Signal from sensor mast up Circuit diagram Ci...

Страница 450: ...lue Status for different mast positions 8 4 11 5 MOVE CAB page MOVE CAB description This group covers tiltable cap functions Confirm selection with function key for Enter 007636 PRESENT OUTPUT SIGNAL...

Страница 451: ...DOORS Description Signal from sensor for opening doors Circuit diagram Circuit 9 6 8 Connection signal from S266 LE 2 to S266 RI 2 to digital in D790 1 K11 3 Function 9 10 2 Doors Signal value page MO...

Страница 452: ...ensor for cab tilt cab in upper position Circuit diagram Circuit 9 10 1 Connection signal from B769 1 C to digital in D797 2 K1 13 Function 9 10 4 Cab tilt Signal value PRESENT INPUT SIGNAL CAB LOWER...

Страница 453: ...05449 PRESENT OUTPUT SIGNAL VALVE CAB UP VALVE CAB DOWN XY XY DIAG MOVE CAB 4 X 00 No output signal open circuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting can only...

Страница 454: ...OUTPUT RIGHT REQUIRED VALUE Description Reference value for control current to control valve for load handling solenoid valve side shift right Circuit diagram Circuit 7 4 1 Connection output signal re...

Страница 455: ...tions the following is also possible XY 01 No output signal PWM off OUTPUT LEFT REQUIRED VALUE Description Reference value for control current to control valve for load handling solenoid valve side sh...

Страница 456: ...9 1 1 Connection signal from S199 2 1 to digital in D790 1 K8 14 Function Signal value OPTION SWITCH S199 3 Description Signal from switch S199 3 Circuit diagram Circuit 9 1 1 Connection signal from S...

Страница 457: ...gital out from D791 1 K1 14 to M693 2 1 Function 9 14 1 Pump unit Signal value 1 Input signal active 0 No signal 005489 PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION FRAME ATTACHMENT XY XY DIAG OPTION 2 X...

Страница 458: ...rcuit in circuit 01 No output signal circuit OK or short circuiting Short circuiting can only be detected when the output signal is ac tive 10 Output signal active short circuiting 11 Output signal ac...

Страница 459: ...OK or short circuiting Short circuiting can only be detected when the output signal is ac tive 10 Output signal active short circuiting 11 Output signal active circuit OK or open circuit Open circuit...

Страница 460: ...Date in format YYYY MM DD page RMI menu 2 SIGNAL QUALITY GSM Description Signal strength of GSM signal through receiver in the RMI interface Circuit diagram Circuit 8 2 4 Connection Function 11 6 5 R...

Страница 461: ...Description Signal strength of SMS signal through receiver in the RMI interface Circuit diagram Circuit 8 2 4 Connection Function 11 6 5 RMI Remote Machine Interface Signal value XXX 0 100 Signal str...

Страница 462: ...e RMI interface Circuit diagram Circuit 8 2 4 Connection Function 11 6 5 RMI Remote Machine Interface Signal value XX XX XX XX Error code ACT ERR Description Internal error code for the RMI interface...

Страница 463: ...t function 1 Menu group 2 Number of menus Because the number of menus depends on machine configuration it is specified as X in this manual 3 Signal value 4 Current variable NOTE Initiation does not ne...

Страница 464: ...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 t...

Страница 465: ...by the limited lowering speed INIT ELSERVO menu 3 page 180 INIT ELSERVO menu 4 page 180 7 3 Extension out INIT ATTACH for DCF360 450CSG page 186 INIT ATTACH menu 2 page 187 7 3 Extension in INIT ATTA...

Страница 466: ...TRAIN menu 10 page 203 2 Transmission automatic engine speed reduction for shift forward reverse INIT DRIVE TRAIN menu 12 page 204 5 2 Power assisted steering system product option lever steering or m...

Страница 467: ...lowering speed INIT ELSERVO menu 15 page 184 INIT ELSERVO menu 16 page 184 7 4 Side shift INIT ELSERVO menu 9 page 182 INIT ELSERVO menu 10 page 182 7 5 Spreading INIT ELSERVO menu 11 page 183 INIT E...

Страница 468: ...o 1st INIT DRIVE TRAIN menu 5 page 202 2 Transmission speed limit declutch INIT DRIVE TRAIN menu 6 page 202 2 Transmission speed limitation gear lock out INIT DRIVE TRAIN menu 10 page 203 2 Transmissi...

Страница 469: ...VDCF03 01GB Workshop Manual DCF 90 100 8 Control system 8 5 1 Initiation 177 7 8 Levelling INIT ATTACH menu 7 page 188 INIT ATTACH menu 8 page 188 Function Menu...

Страница 470: ...alibration 4 Select group by scrolling with the arrow keys 1 and 2 and con firm with Enter Each initiation consists of a sequence of a number of menus The first menu for the selected initiation opens...

Страница 471: ...ENT LIFT Description Start current for activation of solenoid valve lift mast Y6005 PRESENT VALUE Indicates the current value for the start current Adjust the value with the plus and minus keys Save t...

Страница 472: ...r key Go to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for start current Function 7 2 5 Control valve lift and tilt DCF360 450CSG 7 2 6 Contro...

Страница 473: ...n ter key Go to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for max current Function 7 7 5 Control valve lift and tilt DCF360 450CSG 7 7 6 Cont...

Страница 474: ...enu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for start current Function 7 4 5 Control valve load handling DCF 280 330 DCF 370 500 Component Solenoid valve...

Страница 475: ...nt Adjust the value with the plus and minus keys Save the set value with the En ter key Go to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for m...

Страница 476: ...set value with the Enter key Go to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for start current Function 7 2 6 Solenoid valve load handling Co...

Страница 477: ...lue 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 R key STORED VALUE indicates stored...

Страница 478: ...right side out Y6046 4 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...

Страница 479: ...ue with the Enter key Go to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for start current Function 7 3 2 Control valve attachment Component Sol...

Страница 480: ...e XXXmA 0 999 mA INIT ATTACH menu 6 END CURRENT SIDE SHIFT Description Control current at full lever actuation for activation of so lenoid valve for side shift left Y6020 and solenoid valve for side s...

Страница 481: ...ey Go to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for max current Function 7 5 2 Control valve attachment Component Solenoid valve for sprea...

Страница 482: ...key Go to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for max current Function 7 5 2 Control valve attachment Component Solenoid valve for spre...

Страница 483: ...t Solenoid valve for side shift left Y6020 and solenoid valve for side shift right Y6021 Signal value XXXmA 0 999 mA INIT ATTACH menu 6 END CURRENT SIDE SHIFT Description Control current at full lever...

Страница 484: ...to the next menu with the arrow keys Exit initiation with the R key STORED VALUE indicates stored value for max current Function 7 4 2 Control valve attachment Component Solenoid valve for levelling l...

Страница 485: ...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 in percent Function 7 4 2 Control valve attachment Component...

Страница 486: ...NIT ATTACH menu 14 1 Max current END CURRENT 2 Damping PROC DAMPING 3 Start current START CURRENT DAMP PROC SPREADER IN 40 20 Description Percentage damping of control current to solenoid valve for sp...

Страница 487: ...er move ment 31 means that the wheel angle is small at the beginning of the lever movement and large at the end PRESENT VALUE indicates current curve Change curve with the plus or minus keys Save the...

Страница 488: ...speed for BP1 in km h page INIT STEERING menu 3 I mA control current to solenoid valve V kph machine s speed in km h BP1 speed setting for break point 1 BP2 speed setting for break point 2 BP3 speed s...

Страница 489: ...ed for BP3 in km h page INIT STEERING menu 5 I mA control current to solenoid valve V kph machine s speed in km h BP1 speed setting for break point 1 BP2 speed setting for break point 2 BP3 speed sett...

Страница 490: ...t to the solenoid valve for steering right Y636 3 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...

Страница 491: ...eft Y636 4 Signal value XXXmA 0 999 mA page INIT STEERING menu 10 END CURRENT STEERING LEFT Description Control current to the solenoid valve for steering left Y636 4 at end lever position PRESENT VAL...

Страница 492: ...e 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 page INIT DRIVE TRAIN menu 2 VEHIC...

Страница 493: ...escription Setting of highest permitted engine speed for shifting from neutral to gear NOTE This setting takes priority over the setting in INIT DRIVE TRAIN menu 3 page 201 If the engine speed is set...

Страница 494: ...tiation with the R key STORED VALUE indicates saved setting Function 2 Transmission Component Signal value XXX engine speed rpm page INIT DRIVE TRAIN menu 6 VEHICLE SPEED DECLUTCH Description Setting...

Страница 495: ...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 pag...

Страница 496: ...nter 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 page I...

Страница 497: ...tion Start current to solenoid valve side shift right Y6021 at activation of sliding cab The control current controls the start speed for cab sliding to the right PRESENT VALUE Indicates the current v...

Страница 498: ...ght Y6021 Signal value XXXmA 0 999 mA page INIT SLID CAB menu 3 Not used page INIT SLID CAB menu 4 1 Max current END CURRENT 2 Damping PROC DAMPING 3 Start current START CURRENT START CURRENT LEFT Des...

Страница 499: ...s maximum speed cab sliding speed to the left PRESENT VALUE Indicates the current value for max current Adjust the value with the plus and minus keys Save the set value with the En ter key Go to the n...

Страница 500: ...page 210 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 a...

Страница 501: ...rmines which service menu is activated Diag nostic test Initiation or Calibration 4 Select group by scrolling with the arrow keys 1 and 2 and con firm with Enter Each calibration consists of a sequenc...

Страница 502: ...s present load LIFT PRESSURE indicates lift pressure GEAR RATIO MAST indicates gear ratio for the mast CYL AREA indicates cylinder area 8 5 2 2 Calibrate STEERING page Lever steering calibration NOTE...

Страница 503: ...Function 5 2 Power steering system 6 Move steering lever to required position for max angle left 7 Store the position with function key for Enter CALIBR STEERING menu 3 8 STEERING LEVER RIGHT POSITIO...

Страница 504: ...dicates present signal value from Acceler ator pedal B690 1 Function 1 Engine Component Accelerator pedal B690 1 3 Release the accelerator pedal 4 Store the position with function key for Enter DRIVE...

Страница 505: ...ription Calibration of accelerator pedal 2 for driving rear ward on machines with a reversible driver s seat Setting of full throttle position for the accelerator pedal B690 2 STORED VALUE Indicates c...

Страница 506: ...may be reduced towards the end of heating as the oil from the gearbox is too hot If this occurs maintain neutral position and maintain an engine speed of 1200 rpm for 20 sec onds When the temperature...

Страница 507: ...the ignition to store the values 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 applic...

Страница 508: ...VDCF03 01GB Workshop Manual DCF 90 100 216 8 Control system 8 5 2 3 Calibrate DRIVETRAIN...

Страница 509: ...n 20 9 3 6 Compressed air suspended seat 20 9 3 7 Mechanical seat adjustment 21 9 3 8 Passenger seat 21 9 3 9 Armrest 21 9 3 14 Sensor operator in seat 22 9 4 Heating ventilation and air conditioning...

Страница 510: ...ry lighting 74 9 6 14 Work lights front wing 74 9 7 Signalling system 75 9 7 1 Horn 78 9 7 2 Warning lights 79 9 7 3 Rotating beacon 79 9 7 4 Warning parking brake 79 9 7 5 Reversing alarm 79 9 8 Ente...

Страница 511: ...1 8 Reading lamp 103 9 11 9 Writing desk 104 9 12 Chassis 105 9 13 Body 106 9 13 1 Fenders 106 9 13 2 Hood engine compartment 106 9 13 3 Footstep and rail 107 9 13 4 Counterweights 107 9 14 Central lu...

Страница 512: ...VDCF03 01GB Workshop Manual DCF 90 100 4 9 Frame body cab and accessories...

Страница 513: ...ument panel 2 Gear and multi function lever S162 3 Steering wheel panel 4 Steering wheel 5 Switch direction indicators S161 6 Panel for hydraulic functions 7 Switch control switch S250 8 Switch for pa...

Страница 514: ...front wing 20 Switch work lights on carriage and attachment S105 2 Auxiliary work lights carriage and attachment 21 Switch work lights on mast S105 3 Auxiliary work lights mast 22 Switch rotating beac...

Страница 515: ...45 Indicator light travel direction indication 46 Indicator light parking brake 47 Indicator light locked twistlock lock tongue secured load 48 Indicator light alignment attachment load 49 Indicator...

Страница 516: ...horn S149 71 Switch for twistlock lock tongues automatic manual locking S1003 72 Switch spreading 20 40 S1012 73 Switch for spreader stop at 30 or 35 S1004 74 Spare 75 Switch for automatic manual cab...

Страница 517: ...ting menu engine 9 Operating menu heating and air conditioning 3 Operating menu for oil temperature 10 Operating menu code lock 4 Operating menu electrical system 11 Operating menu statistics operatin...

Страница 518: ...stlocks 1 Event menu start interlock 2 Event menu twistlock alignment 3 Event menu twistlocks 4 Event menu open door 5 Event menu automatic spreading Event menus overview Side lifting attachment with...

Страница 519: ...n at slow interval wiping 1 Slow interval wiping windscreen controls slow interval wiping for roof window and rear window 2 Fast interval wiping front windshield controls fast interval wiping for roof...

Страница 520: ...s 2 x hexagonal socket bolts 3 Unplug the connector from the KIT control unit D790 2 4 Fit a new lever and refit the dashboard panel 9 1 22 Switch direction indicators page Switch direction indicators...

Страница 521: ...t belt depending on the type of seat fitted in the machine The seat belt is mounted on the seat 9 2 3 Fire extinguisher page Fire extinguisher description The fire extinguisher sits at the entry on th...

Страница 522: ...ts description product alternative standard seat Controls standard seat 1 Lumber support adjustment 2 Right armrest adjustment 3 Left armrest adjustment 4 Backrest rake adjustment 5 Springing position...

Страница 523: ...e 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 spe cial compressor installe...

Страница 524: ...Backrest rake 7 Damping adjustment 8 Seat heating 9 Plane damping off on 10 Lumber support adjustment 11 Armrest The seat s function is to give the operator a good sitting position and contribute to a...

Страница 525: ...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 D...

Страница 526: ...rubber bellows by removing the plastic clips position 1 3 Unhook the upholstery s rails position 2 from the seat frame po sition 3 and remove the upholstery 4 Remove the padding position 4 If the sea...

Страница 527: ...n 5 Remove the armrest by removing the attaching bolts position 6 6 Place the backrest on the seat and install the attaching bolts po sition 1 do not tighten Then install the attaching bolts for the s...

Страница 528: ...ee Back cushion changing product alternative BE GE page 19 5 Remove the shock absorber s attaching bolts position 2 and 3 6 Replace shock absorber position 1 7 Assemble in reverse order 9 3 5 Air susp...

Страница 529: ...product alternative Bege 9120 page 15 Seats description product alternative Isringhausen 6800 page 16 9 3 8 Passenger seat page Passenger seat description Passenger seat with bracket The passenger se...

Страница 530: ...used to allow the control system to in dicate with the operator in seat buzzer H853 if the operator leaves the machine without applying the parking brake The sensor also ena bles the control system to...

Страница 531: ...ture The temperature can be set between 16 and 27 C The unit is operated with controls on the instrument panel Heating system EHC The heating system EHC handles heating and ventilation The heat ing sy...

Страница 532: ...0 2 5 V Unaffected U 0 0 5 V Lower U 4 5 5 0 V Controls and instruments overview page 5 D1 Diagnostic menu see section 8 Control system group 8 4 4 5 CLIMATE menu 5 2 The fan switch S118 sends a volta...

Страница 533: ...at the cab air 9 The cab control unit D790 1 controls the water valve Y673 which directs hot water to heat exchanger heating The water valve s opening is sent back to the cab control unit D790 1 This...

Страница 534: ...ies voltage to the compressor s electromag netic clutch 645 U 24 V AC compressor description page 43 D17 Diagnostic menu see section 8 Con trol system group 8 4 4 6 CLIMATE menu 6 18 The compressor dr...

Страница 535: ...emperature in refrigerant descrip tion page 51 D23 Diagnostic menu see section 8 Con trol system group 8 4 4 2 CLIMATE menu 2 24 Heat exchanger cooling dissipates heat from the cab air Heat is transfe...

Страница 536: ...rant B775 1 If the compressor is activat ed the value will be low However if heat has been selected and the compressor is deactivated the value will almost be equal to TEMP COIL Menu 3 7 Only machines...

Страница 537: ...g with your hand Only machines with ECC COMPRESSOR lower temperature setting to max cooling after approx 45 seconds the compressor will be activated and the dis play should show 11 NOTE Compressor act...

Страница 538: ...hanges 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...

Страница 539: ...lter page Fresh air filter description The fresh air filter is located under a cover in the external unit for fresh air intake into the cab in front of the cab fan A finer filter can be used but this...

Страница 540: ...description The damper is controlled electrically and controls the air between fully open for fresh air to recirculation of air The damper is located in the external unit for fresh air intake into the...

Страница 541: ...recirculation damper 33 page 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 wipe...

Страница 542: ...body cab and accessories 9 4 2 Fresh air and recirculation damper 6 Remove the bolts which secure the arm and motor in the plate 7 Detach the connector from the motor 8 Replace the motor 9 Fit in the...

Страница 543: ...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 sect...

Страница 544: ...00 36 9 Frame body cab and accessories 9 4 3 Cab fan 3 Remove the bolts which secure the wiper motor in the protective plate 4 Remove the protective plate 5 Detach the washer hose from the protective...

Страница 545: ...me body cab and accessories 9 4 3 Cab fan 37 7 Remove the bolts which secure the plate and cab fan 8 Detach the connector from the cab fan 9 Remove the cab fan 10 Replace the cab fan 11 Fit in the rev...

Страница 546: ...ger heat description Fresh air intake cab 1 Heat exchanger heat 2 Heat exchanger cooling 3 Expansion valve and sensor for refrigerant temper ature The heat from the engine s coolant is transmitted to...

Страница 547: ...34a refrigerant 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 t...

Страница 548: ...GB Workshop Manual DCF 90 100 40 9 Frame body cab and accessories 9 4 4 Heat exchanger heat 8 Remove the fresh air filter 9 Remove the plate frame 10 Remove the cab fan 11 Remove the heat exchanger co...

Страница 549: ...th refrigerant R134a with the intended equipment For volume see section F Technical data 9 4 5 Water valve page Water valve description Water valve position under cab floor from below The water valve...

Страница 550: ...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 9 4 6 Engine te...

Страница 551: ...hermostat The signal can be checked from the diagnostic menu see section 8 Control system group 8 4 4 6 CLIMATE menu 6 page AC compressor replacement The illustration depicts the compressor for Volvo...

Страница 552: ...ew oil through the compressor s suction connection 10 Fit the new compressor and other equipment in reverse order 11 Check for leaks and refill the AC system with refrigerant R134a with the intended e...

Страница 553: ...locking washer and the outer lock ring 5 Remove the groove 6 Remove the three screws securing the electromagnetic clutch 7 Remove the electromagnetic clutch 8 Fit in the reverse order 9 Check the fun...

Страница 554: ...varies from ap prox 50 C to 70 C and the pressure varies between 12 and 14 bar depending on ambient temperature and airflow through the condens er When the refrigerant has been condensed to liquid it...

Страница 555: ...t glass NOTE For tightening torque of refrigerant hoses and pressure switch see section F Technical data The moisture filter collects the liquid refrigerant binds moisture and fil ters impurities The...

Страница 556: ...e switch 3 Sight glass NOTE For tightening torque of refrigerant hoses and pressure switch see section F Technical data The pressure switch cuts off the current to the compressor s electro magnetic cl...

Страница 557: ...tion The expansion valve is the part in the circuit that separates the high pressure side from the low pressure side The refrigerant arrives at the expansion valve under high pressure and leaves it un...

Страница 558: ...ss the ex pansion valve see Heat exchanger cooling heating replace ment page 39 6 Replace the expansion valve 7 Fit in the reverse order 8 Check for leaks and refill the AC system with refrigerant R13...

Страница 559: ...see section 8 Control system group 8 4 4 2 CLIMATE menu 2 page Sensor refrigerant temperature replacement NOTE Requires special authorization 1 Machine in service position see section B Safety 2 Drai...

Страница 560: ...9 4 12 Sensor temperature refrigerant 7 Fit in the reverse order 8 Check for leaks and refill the AC system with refrigerant R134a with the intended equipment For volume see section F Technical data...

Страница 561: ...hanger cooling 3 Expansion valve and sensor for refrigerant temper ature The heat exchanger for cooling consists of pipes and cooling fins The cab air is cooled as it passes through the cooling heat e...

Страница 562: ...enu 4 and 8 4 4 5 CLI MATE menu 5 and 8 4 4 8 CLIMATE menu 8 page Air distributor replacement 1 Machine in service position see section B Safety 1 Instrument panel 2 Steering wheel shaft adjustment 3...

Страница 563: ...doors and the defroster for the windshield There are also two adjustable air vents flow and direction in the instrument panel s out side corners There is an air inlet towards the cab s lower part flo...

Страница 564: ...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 secti...

Страница 565: ...ure page Sensor cab temperature description 1 Sensor cab temperature 2 Sensor temperature refrigerant 3 Sensor temperature outlet fan The cab temperature sensor position 1 detects the temperature of t...

Страница 566: ...ge Sensor ambient temperature description Sensor outdoor temperature The ambient temperature sensor detects the temperature of the air outside the cab The signal can be checked from the diagnostic men...

Страница 567: ...ting unit which uses residual heat in the engine s cooling system to keep the cab warm An extra electrically operated water pump pumps the coolant through the heater unit when the engine is stopped Th...

Страница 568: ...Wiping angle is approx 180 degrees 9 5 3 Wiper rear page Wiper rear description The rear wiper is a sector wiper type The wiping angle is approx 180 degrees 9 5 4 Washer motor and reservoir page Washe...

Страница 569: ...e cab wall 6 Change the washer fluid reservoir Change the washer motor if needed 9 5 5 Wiper motor front page Wiper motor front description The wiper motor drives the front windscreen wiper The wiper...

Страница 570: ...Nm 9 5 6 Wiper motor roof page 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 signa...

Страница 571: ...motor drives the rear window wiper The wiper arm is mounted on the motor The motor produces the movement of the wip er The signal can be checked from the diagnostic menu see section 8 Control system...

Страница 572: ...DCF 90 100 64 9 Frame body cab and accessories 9 5 7 Wiper motor rear 6 Remove the screws securing the motor and the lock nut on the motor 7 Replace the wiper motor 8 Fit in the reverse order Tighten...

Страница 573: ...26 D27 D20 D31 D33 D34 D16 D28 D29 D18 D19 D1 D2 D3 D5 D4 D15 D9 D11 D10 Pos Explanation Signal description Reference 1 The switch for cab roof work lights S105 1 sends a voltage signal to the cab con...

Страница 574: ...on page 11 D9 Diagnostic menu see section 8 Control system group 8 4 2 3 LIGHTS menu 3 10 The direction indicator lever S161 sends a voltage signal to the KIT control unit D790 2 Left US161 6 24 V Rig...

Страница 575: ...hen the inte rior lighting comes on Light on U 24 V Entry lighting description page 74 D19 Diagnostic menu see section 8 Control system group 8 4 2 15 LIGHTS menu 15 20 The brake light NO switch S216...

Страница 576: ...tion 8 Control system group 8 4 2 11 LIGHTS menu 11 30 The frame control unit D797 2 supplies volt age to the machine lights Checked by control sys tem error shown with error code Section 11 Common el...

Страница 577: ...S141 4 Multi function lever S162 19 Frame control unit option D797 2 5 Control unit KIT D790 2 20 Frame control unit D797 1 6 Interior lighting E434 1 21 NO switch brake lights S216 7 Cab roof work l...

Страница 578: ...signal can be checked from the diagnostic menu section 8 Control system group 8 4 2 2 LIGHTS menu 2 9 6 3 Tail light page Tail light description Tail lights are located in the rear of the machine to p...

Страница 579: ...h lever for direction indicators The signal travels to the frame control unit D797 1 The lights and their signal can be checked from the diagnostic menu see section 8 Control system group 8 4 2 4 LIGH...

Страница 580: ...k lights page Work lights changing product alternative Xenon lights NOTE The xenon light is filled with different gases and metals Replaced xenon headlights should be considered as hazardous waste and...

Страница 581: ...rkness Brightness is controlled by the plus and minus keys The lights and their signal can be checked from the diagnostic menu section 8 Control system group 8 4 2 9 LIGHTS menu 9 9 6 12 Work lights a...

Страница 582: ...up 8 4 2 15 LIGHTS menu 15 9 6 14 Work lights front wing page Front wing work lights lighting Work lights on the front wing provide enhanced view when load han dling in darkness The work lights are co...

Страница 583: ...l unit D790 1 Switch in ON position U 24 V D2 Diagnostic menu see section 8 Control system group 8 4 2 4 LIGHTS menu 4 3 The parking brake switch S107 sends a voltage signal to the cab control unit D7...

Страница 584: ...ar engaged U 24 V Reversing alarm description page 79 D12 Diagnostic menu see section 8 Control system group 8 4 2 8 LIGHTS menu 8 13 Horn H850 sounds when the horn is activated Horn active U 24 V Hor...

Страница 585: ...control sys tem error shown with er ror code Section 11 Common electrics group 11 5 3 5 Attachment control unit D791 1 21 The automatic spreading buzzer H9003 is activated when automatic spreading 20...

Страница 586: ...tic menu see section 8 Control system group 8 4 3 5 CAB menu 5 008395 17 18 19 16 15 14 13 12 9 8 7 10 11 1 2 3 4 5 6 1 Control unit KID D795 11 Control unit cab D790 1 2 Buzzer cab H853 12 Make conta...

Страница 587: ...ap plies the parking brake A sensor in the driver s seat see Sensor operator in seat description page 22 indicates to the control system if the operator leaves the seat The buzzer is located in the st...

Страница 588: ...Entertainment and communication page Entertainment and communication general The machine is prepped with a connector for customer accessories see section 11 Common electrics group 11 5 2 1 Electrical...

Страница 589: ...ive handling advice The window panes are secured with key adhesive and silicone adhe sive NOTE The purpose of this instruction is to describe how silicone adhe sive 923854 0100 should be handled in co...

Страница 590: ...indshield consists of the front window and side windows The windshield is attached to the cab with a key strip and is glued to the roof window with silicone adhesive Front and side windows are joined...

Страница 591: ...the top edge of the roof see figure 2 and so that the distance between windshield and side window is as shown in figure 3 Use spacers against the roof member to ensure that the distanc es are obtaine...

Страница 592: ...a uniform distance of one or several millimetres along the window pane s edges and by the protection over the frame s sides Then tighten the corner bolts for the window pane 13 Apply silicone adhesiv...

Страница 593: ...and accessories 9 9 2 Side window 85 2 Use special tools to detach the wedge strip 3 Remove the wedge strip which runs around the whole window 4 Carefully remove any glass remains from the rubber str...

Страница 594: ...ccessories 9 9 2 Side window 6 Spray soap solution on the window and rubber strip to facilitate fitting 7 Thread the rubber strip around the whole window use special tools 8 Secure the wedge strip wit...

Страница 595: ...DCF 90 100 9 Frame body cab and accessories 9 9 2 Side window 87 10 Cut off the wedge strip approx 2 cm too long 11 Fit the other end of the wedge strip edge to edge 12 Adjust the wedge strip so that...

Страница 596: ...roof window is combined with the windscreen The joint is sealed with silicone Add a new silicone seal when replacing 9 9 4 Rear window page Rear window description The rear window is attached to the c...

Страница 597: ...eating which is acti vated at ambient temperatures below 10 C The reversing camera sends colour images and audio to the monitor in the cab see Monitor reversing camera description page 89 9 9 7 Monito...

Страница 598: ...ercarriage via strong rubber insulators located on the underside of the cab This minimises vibrations from the frame to the cab There is an insulator at four points one at each cor ner Each insulator...

Страница 599: ...terior lighting and warn of an open door The signal can be checked from the diagnostic menu see section 8 Control system group 8 4 2 9 LIGHTS menu 9 or 8 4 11 5 MOVE CAB menu 1 9 10 3 Cab undercarriag...

Страница 600: ...tilt po sition the cab will be tilted when the mast reaches a predetermined lift height The cab can be tilted up or down with the manual cab tilt switch This switch is also operative when the cab til...

Страница 601: ...11 1 P LS LSPB T TP B A 10 6 8 9 4 5 7 2 0 1 3 0 1 D790 1 D797 1 D797 2 D3 D4 D6 D8 D9 010028 Pos Explanation Signal description Reference 1 The cab tilt shuttle valve sends a load signal to the hydra...

Страница 602: ...wn on the CAN bus Checked by control sys tem error shown with er ror code Section 11 Common electrics group 11 5 3 2 Frame control unit D797 1 8 The cab up sensor B769 1 and cab down sensor B769 2 pro...

Страница 603: ...e reduction valves servo valves con vert electric current to a small hydraulic pressure which is proportional to the current so called servo pressure The servo pressure operates a spring centred contr...

Страница 604: ...to protect the hydraulic system from impurities 4 Mark up and detach the wiring from the control valve 5 Remove the control valve Remove the attaching bolts and lift away the valve Place the valve on...

Страница 605: ...ss Top up as needed 9 10 4 3 Cab tilt shuttle valve page Cab tilt shuttle valve description Cab tilt shuttle valve See section 10 Common hydraulics group 10 5 3 Shuttle valve CAUTION Air in the hydrau...

Страница 606: ...ake valve description Cab tilt brake valves There are two brake valves situated between the cab tilt control valve and the cab tilt cylinders The brake valves are adjustable and choke pressure to the...

Страница 607: ...part that holds the cab has a hinge at the trailing edge which is located on the frame and the hydraulic cylinders are located at the leading edge be tween the parts 9 10 4 7 Sensor for automatic cab...

Страница 608: ...its lower position machine speed is reduced to not more than 5 km h The signal can be checked from the diagnostic menu see section 8 Control system group 8 4 11 5 MOVE CAB menu 3 page Position sensor...

Страница 609: ...nt 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 which is mounted on the driver s sea...

Страница 610: ...or from the multi function levers ignition switch KIT control unit D790 2 and KID control unit D795 7 Transfer the components to the new steering wheel cover 8 Fit in the reverse order 9 11 2 Interior...

Страница 611: ...reen 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 hook...

Страница 612: ...b and accessories 9 11 9 Writing desk 9 11 9 Writing desk page Writing desk description The writing table with reading light is located on a flexible attachment to the right in front of the door in th...

Страница 613: ...hydraulic tanks cab mast and body parts The space in the rear section of the frame is used for counterweights the number of which is adapted to the machine in question The coun terweights are designe...

Страница 614: ...sign of the counterweight see Coun terweight description page 107 acts as a mudguard for the rear wheels The fenders can be equipped with extra mudguards when the ma chine s work environment requires...

Страница 615: ...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 counte...

Страница 616: ...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 l...

Страница 617: ...re pressed out at all grease points pause time can be increased NOTE Adjust only one step each time Small adjustments make a big difference Test or extra greasing Central lubrication can be operated m...

Страница 618: ...d run ning time as well as read in time In the pump there is a circuit board with a timer with which one can set the pump motor s run and pause time When the central lubrication works it greases the g...

Страница 619: ...on each other It is technically impossible to skip any connected grease point If a grease point cannot be greased the whole system is blocked and grease is pressed out through the safety valve The sys...

Страница 620: ...coatings 9 15 Paint coatings page Paint coatings description The machine is painted using a single layer paint thickness 120 my For colour code RAL of machine in question see machine card Please conta...

Страница 621: ...4 2 Axial piston pump with variable displacement 9 10 4 3 Pipes and hoses 18 10 5 Hoses pipes and valves 19 10 5 1 Pipes and hoses 19 10 5 2 Priority valve 20 10 5 3 Shuttle valve 20 10 5 5 Collectin...

Страница 622: ...VDCF03 01GB Workshop Manual DCF 90 100 2 10 Common hydraulics...

Страница 623: ...The accumulator drain valve is located on the accumulator charging valve See section 4 Brakes group 4 3 3 Accumulator charging valve 10 2 2 Attachment relief valve page Attachment relief valve descri...

Страница 624: ...ressure in the hydraulic oil supply to tank protecting the hydraulic system against excessive pressures The pressure limiting valve sits on the collecting block for pressure supply from the load handl...

Страница 625: ...e through hatches on top of the tank Hydraulic oil is filled directly into the tank through the filler caps on the filter manhole covers For oil capacity and grade see section F Tech nical data The en...

Страница 626: ...culates hydraulic oil through the radiator and filter see section 4 Brakes group 4 3 1 Hydraulic oil pump The gear pump pumps oil using two gears wheels that rotate opposite each other One is driven b...

Страница 627: ...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 o...

Страница 628: ...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 NOTE Check that the accumulator drain valve is fully c...

Страница 629: ...ng on the flow demand from each function Three pumps of which two are assembled with a junction block sup ply the working hydraulics The junction block controls oil to and from the pumps On the juncti...

Страница 630: ...sion on left frame mem ber Section 7 Load handling group 7 2 5 Lift and tilt control valve 2 The steering shuttle valve sends the load signal on to the hydraulic oil pump for steering and load handlin...

Страница 631: ...e tank quick lift hydraulic oil pump off Section 7 Load handling group 7 2 12 Quick lift valve block 10 The quick lift hydraulic oil pump in creases the flow See pressure plate Max pressure hydraulic...

Страница 632: ...c oil pump for load han dling increases the flow to the cab tilt control valve See pressure plate Max pressure hydraulic oil pumps on left frame member Axial piston pump with variable displace ment de...

Страница 633: ...ering and load handling 3 0 MPa Hydraulic oil pump for quick lift 2 8 MPa Hydraulic oil pump for load handling 2 6 MPa The settings apply to standard machine certain machines can have higher stand by...

Страница 634: ...he hydraulic systems See section B Safety 4 Detach the gear pump from the hydraulic oil pump see Gear pump changing page 6 in order to replace the pump for steering and load handling 5 Suspend the gea...

Страница 635: ...t mates with the gearbox see section F Technical data 13 Fit the axial piston pump in place Place the axial piston pump so that the pump shaft engages the transmission s gears Install the attaching bo...

Страница 636: ...nly use silicon on one side the side against the brake pump 18 Fit the spacer ring on the axial piston pump The illustration shows a separate pump 19 Brush sealing silicone on the gear pump s sealing...

Страница 637: ...t the hose connections and seal between gear pump and axial piston pump are airtight 25 Check the pump pressures see Hydraulic oil pump checking page 13 26 Check the oil level in the hydraulic oil tan...

Страница 638: ...lic system s feed from the axial piston pump one at a time and let oil flow out Tighten the connec tions when oil free of air flows out 4 Remove the compressed air from the tank and fit the breather f...

Страница 639: ...not be oiled when fitted C L line for measuring hose length Hose length Hose length is measured on a laid out hose between the sealing sur faces On angled connections measure from the sealing surface...

Страница 640: ...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 t...

Страница 641: ...he hydrau lic oil pump for load handling see Axial piston pump with variable displacement description page 9 3 Chooses between the load signal from the attachment shuttle valve position 1 or the cab t...

Страница 642: ...perature sensor and bypass valve The hydraulic oil pump for the brake system pumps oil from the tank through the brake system s cooling circuit to be cooled in the hydraulic oil cooler Some of the oil...

Страница 643: ...lve directs oil to charging of accumulators or through the brake system s cooling circuit Charge P 20 5 0 5 MPa Cooling P 0 1 MPa See Section 4 Brakes group 4 3 3 Ac cumulator charging valve 4 The oil...

Страница 644: ...cription page 27 12 If the pressure through the cooler is too high the thermal bypass valve opens and directs the oil past the cooler P 0 2 MPa Cooler bypass valve description page 29 13 If the hydrau...

Страница 645: ...AC Higher voltage generates higher heater output The heater is mounted in a hole in the connection cover at the bottom of the short side of the tank The tank heater can be equipped with a programmable...

Страница 646: ...B Safety 1 Machine in service position see section B Safety 2 Drain the oil from the hydraulic oil tank see Hydraulic oil chang ing page 32 1 Cooling fan 2 Hydraulic connections 3 Cooler 3 Mark up and...

Страница 647: ...e checked from the diagnostic menu see section 8 Control system group 8 4 5 1 HYD menu 1 10 6 4 Sensor hydraulic oil temperature page Sensor hydraulic oil temperature description The hydraulic oil tem...

Страница 648: ...temperature B776 4 Change sensor hydraulic oil temperature B776 NOTE Check that the O rings are intact and fitted correctly 5 Connect the cabling to the sensor 6 Fill the hydraulic oil tank with oil...

Страница 649: ...see section B Safety Bypass valve 1 Machine in service position section B Safety 2 Depressurize the hydraulic systems See section B Safety 3 Drain the oil from the hydraulic oil tank see Hydraulic oil...

Страница 650: ...tank to protect the tank from impurities On top of the filter housing is an indi cator that shows when the filter is clogged and should be changed 10 6 7 Oil filter page Hydraulic oil filter descript...

Страница 651: ...lic oil drain 4 Part the filter unit and remove the filter insert Handle the filter in sert as environmentally hazardous waste Note the position of the parts Magnetic rod 5 Clean the filter holder s p...

Страница 652: ...container under the hydraulic oil tank s drain plug and drain the last of the hydraulic oil 4 Fit the drain plug when the oil has drained NOTE Make sure that the seal washer is installed as well 5 If...

Страница 653: ...d 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 page Hydraulic oil fine filter replacement NOTE...

Страница 654: ...VDCF03 01GB Workshop Manual DCF 90 100 34 10 Common hydraulics 10 6 10 Pipes and hoses 10 6 10 Pipes and hoses page Pipes and hoses general See Pipes and hoses general page 19...

Страница 655: ...heck 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 fault...

Страница 656: ...mium 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 pi...

Страница 657: ...fixed There are different types of piston rod seals Single V ring seal 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 o...

Страница 658: ...ace 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...

Страница 659: ...ling surface 5 Cylinder head sealing surface 6 Screwdriver 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 sc...

Страница 660: ...1 Correct fitting tool 2 Scraper correctly fitted 3 Cylinder head 4 Play between scraper and bottom of cylinder head recess 5 Incorrect fitting tool 6 Deformed scraper Scraper The purpose of the scra...

Страница 661: ...ston sealing surface 6 Screwdriver 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 mov ing surface To remove...

Страница 662: ...re extremely important that it is completely free from dam age Exercise care when fitting the piston in the cylinder barrel making sure that the seal is not damaged by the cylinder barrel threads Dism...

Страница 663: ...nd work the surrounding material inwards towards the damage starting from the outside 3 Instead of a small sharp mark there will now be a small uniform concavity in the chromium plating 4 Polish with...

Страница 664: ...e 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...

Страница 665: ...ses 3 11 2 3 Emergency stop switch 3 11 3 Batteries 4 11 3 1 Start battery 4 11 4 Alternator 6 11 4 1 Alternator 6 11 5 Electrical distribution 7 11 5 1 Power supply 7 11 5 2 Electrical distribution b...

Страница 666: ...VDCF03 01GB Workshop Manual DCF 90 100 2 11 Common electrics...

Страница 667: ...placing the main fuse 1 Switch off the main current battery disconnect switch 2 Remove the plastic cover 3 Check that fuses are intact Replace if necessary The fuses are 50 A When checking and replaci...

Страница 668: ...sulphuric acid Risk of corrosive injuries health hazard Immediately remove electrolyte from the skin Wash with soap and copious amounts of water If electrolyte gets in the eyes rinse with copious amo...

Страница 669: ...ne 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 termin...

Страница 670: ...pplies this to the batteries The alternator produces AC current and has an integrat ed charge regulator The alternator is driven by the engine via a belt Faults are indicated by the warning lamp for l...

Страница 671: ...ion 8 Control system group 8 4 2 9 LIGHTS menu 9 or 8 4 11 5 MOVE CAB menu 1 2 The interior lighting switch of the KIT control unit D790 2 sends a voltage signal to the cab control unit D790 1 U 24 V...

Страница 672: ...ction of one voltage feed the control unit is supplied by the other feed UK11 7 24 V UK11 8 24 V UK11 9 24 V UK11 10 24 V Cab control unit D790 1 description page 18 8 The cab control unit D790 1 sup...

Страница 673: ...scription Reference 1 The switch for warning lights S109 sends a voltage sig nal to the cab control unit D790 1 U 24 V Section 9 Frame body cab and accessories group 9 6 7 Warning lights D1 Diagnostic...

Страница 674: ...tage to the cab control unit D790 1 UK1 2 24 V UK1 3 24 V UK1 4 24 V Cab control unit D790 1 description page 18 D8 Diagnostic menu see section 8 Control system group 8 4 1 7 CAN POWER menu 7 9 Igniti...

Страница 675: ...794 D790 1 7 8 3 4 6 K3002 K3007 K3009 1 K3009 2 D8 D2 D4 D5 D7 Pos Explanation Signal description Reference 1 Ignition voltage is activated by the cab con trol unit D790 1 Checked by control system e...

Страница 676: ...gen cy stop switch is not pressed in The control unit on the attachment is only supplied emergency stop switch voltage thus all attachment functions stop if the emergency stop switch is activated If t...

Страница 677: ...d check that the lift function works again 11 5 1 5 Voltage converter page Voltage converter description The voltage converter is located under a protective casing to the left behind the driver s seat...

Страница 678: ...Voltage converter replacement The voltage converter is located behind the driver s seat 1 Machine in service position see section B Safety 2 Remove the covers behind the driver s seat 3 Detach the el...

Страница 679: ...e Control unit cab D790 1 Circuit fuses for cab battery voltage 30 ignition voltage 15 F58 4 and circuit fuses for cab ignition voltage 15 F58 5 Buzzer for alarm if for example the operator leaves the...

Страница 680: ...793 8 Attachment connection terminal 9 Lift lower relay K3007 10 Tilt in out relay K3002 11 Ignition switch relay K315 2 12 Ignition switch power relay K315 1 13 Emergency stop switch power relay K300...

Страница 681: ...l units position 009172 3 5 7 9 2 6 4 8 1 1 Control unit attachment D791 1 6 Control unit Volvo engine D794 2 Control unit KID D795 7 Control unit Cummins engine D794 3 Control unit KIT D790 2 8 Frame...

Страница 682: ...unction see illustration page Control unit cab change 1 Machine in service position see section B Safety 2 Remove the cover from the electrical distribution box 3 Unplug the cab control unit D790 1 co...

Страница 683: ...ee section B Safety 2 Detach the cables from the frame control unit D797 1 3 Change control unit 4 Check that the new control unit matches the machine s forklift number Z number 5 Calibrate the new co...

Страница 684: ...section B Safety 2 Detach the cables from the frame control unit KDU D797 2 3 Change control unit 4 Check that the new control unit matches the machine s forklift number Z number 5 Calibrate the new c...

Страница 685: ...section B Safety 2 Disconnect the cabling from the control unit 3 Change control unit 4 Check that the new control unit matches the machine s forklift number Z number 5 Check the initiation values fo...

Страница 686: ...used to navigate in the display and select display group and status in formation The following status information can be shown in the display Display group I GPOS shows transmission s direction of rot...

Страница 687: ...e control unit EDC D794 is connected via separate CAN bus communication to the transmission which is connected to the cab control unit D790 1 The cab control unit D790 1 sends drivetrain information o...

Страница 688: ...control unit is located on the engine has no function keys or dis play All functions are controlled via the CAN bus and an external con trol system The control unit monitors the following values to op...

Страница 689: ...panel for warning and indicator lights 1 The KIT control unit D790 2 has several individual function keys and indicator lights see illustration See the operator s manual for detailed information on wa...

Страница 690: ...or detailed information on the display page KID control unit D795 replacement 1 Machine in service position see section B Safety 2 Remove the steering wheel and open the steering wheel panel 3 Detach...

Страница 691: ...r X005 Control unit cab D790 1 Switch left panel Switch option Window washer roof rear Switch warning light Hazard Setting fan speed Setting temperature Air distribution Fan and recirculation controls...

Страница 692: ...Lever steering or mini wheel Switch horn X009 2 Control unit cab D790 1 Control lever X010 Control unit cab D790 1 Sensor alignment Water valve Horn Relay seat heating Relay work lighting Hour counter...

Страница 693: ...r Switch direction indicators Switch interior lighting X020 Control unit KID D795 CAN bus RS232 Power supply and earth connection Control unit KID D795 X033 Air conditioning system Control fan Control...

Страница 694: ...1 X051 Electrical distribution box cab Feedback relay K3009 1 Power supply Control unit cab D790 1 CAN bus X052 Electrical distribution box cab CAN bus Control relays K315 1 K3009 1 K3009 2 and K315...

Страница 695: ...Actuator recirculation X063 Electrical distribution box cab Sensor operator in seat Seat heater Compressed air damped seat X065 Electrical distribution box cab Ambient temperature sensor X066 Electric...

Страница 696: ...me Power supply attachment control unit X201 Electrical distribution box frame Earth connection and power supply Control unit transmission D793 X203 Electrical distribution box frame Termination resis...

Страница 697: ...frame control unit D797 2 Emergency stop switch voltage X230 Beneath driver s seat Sensor operator in seat X235 Front edge of frame Lift lower valve Tilt valve Mast valves X240 Front edge of frame Po...

Страница 698: ...p bracket left front Main and dipped beams Driving direction indicator Side marker lights X271 Lamp bracket front Main and dipped beams Driving direction indicator Side marker lights X272 Lamp bracket...

Страница 699: ...nt control unit D791 42 pin connector for Control unit attachment D791 X422 Attachment control unit D791 Power supply and earth connection Control unit attachment D791 CAN bus Control unit attachment...

Страница 700: ...VDCF03 01GB Workshop Manual DCF 90 100 36 11 Common electrics 11 5 5 Cables X901 Voltage converter cab Voltage converter 24 V 12 V Socket 24 V Connec tor Location Function...

Страница 701: ...modulated signal is a digital signal translated to an analogue continu ous signal adapted for a purpose such as solenoid valve control When the spool in a solenoid valve gets hot resistance drops Thi...

Страница 702: ...gh side driver 10 A Logic one 1 generates voltage out U 22 5 V Max load 10 A Open load 1 9 A Max instantaneous current load 70 A E g cooling fan This output is only found on the frame and attach ment...

Страница 703: ...in 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 Message Messages run in time...

Страница 704: ...ecommended 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 c...

Страница 705: ...umber of active segments depends on the number of control units the machine has which depends on the machine s equipment level options Segment numbering with optional equipment without cab tilt The ne...

Страница 706: ...the control nodes ensure communication segment by segment A clicking sound is audi ble when then termina tion resistor is activated Attachment control unit D791 description page 21 Diagnostic menu se...

Страница 707: ...section 8 Control system group 8 4 1 4 CAN POWER menu 4 5 The KID control unit D795 sends a re sponse back on the CAN bus via CAN L and sends the request on via CAN R Termination resistors in the cont...

Страница 708: ...r com munication with engine alternative Volvo that varies Sockets for programming control units in electrical distribution box cab position 1 are used for programming the control units in the cab on...

Страница 709: ...ords the communication on the CAN bus and sends the information to a central RMI server The control unit in the machine can sends the information via GSM GPRS WLAN Radio modem SMS or e mail in case of...

Страница 710: ...VDCF03 01GB Workshop Manual DCF 90 100 46 11 Common electrics 11 6 5 RMI Remote Machine Interface...

Страница 711: ...des 3 Error codes explanation 3 Error code menu description 4 Reading out error code 7 1 Engine 9 Error codes engine general 9 Error codes engine engine alternative Cummins QSB6 7 11 Error codes engin...

Страница 712: ...VDCF03 01GB Workshop Manual DCF 90 100 2 D Error codes...

Страница 713: ...ne 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...

Страница 714: ...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 immediatel...

Страница 715: ...eral error codes come from the engine the error code level is shown for the most serious error code Transmission Shown with error code number XX YY on display Field D Type of error 1 Too high too low...

Страница 716: ...n 8 Tilt forks 9 Side shift forks 10 Spreading forks 11 Rotation forks 12 Overload protection 13 Hydraulic functions 14 Brake system 15 Steering 16 Engine 17 Transmission 18 Central lubrication 19 Con...

Страница 717: ...Safety menu is shown Hold Enter depressed for at least two sec onds 4 The error code list is shown on the display Active error code is shown on display where field C shows error code number togeth er...

Страница 718: ...own 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...

Страница 719: ...oltage 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 mechani...

Страница 720: ...DCF03 01GB Workshop Manual DCF 90 100 10 D Error codes 1 Engine 31 FMI is not available or the condition that is identified by the SPN exists Not available or condition exists FMI Description SAE text...

Страница 721: ...gnal indicates an intermit tent connection or VSS tam pering Engine speed limit ed to Maximum En gine Speed without VSS parameter val ue Cruise control Gear Down Protec tion and Road Speed Governor wi...

Страница 722: ...091 4 Accelerator Pedal or Lever Position Sensor Circuit Voltage Below Normal or Shorted to Low Source Low voltage detected at acceler ator pedal or lever position signal circuit Severe derate in powe...

Страница 723: ...een con trol unit and component Check the sen sor D794 97 15 P097 0 Water in fuel indicator Data valid but above normal operational range least se vere level Water has been detected in the fuel filter...

Страница 724: ...it None on perform ance Check oil level in the engine top up as need ed ENGINE menu 6 102 2 P102 2 Intake Manifold Pressure Sensor Circuit Data Erratic Intermittent or Incorrect The ECU 794 has detect...

Страница 725: ...e ECU 794 uses an estimated turbocharger speed Check the component D794 105 0 P105 0 Intake Manifold 1 Tempera ture Data Valid but Above Normal Operational Range Most Severe Level Intake manifold air...

Страница 726: ...in the engine top up as needed Check that the charge air cooler is clean clean as need ed Check that fan belts are intact Check the sen sor D794 ENGINE menu 7 108 2 P108 2 Barometric pressure Data er...

Страница 727: ...conditions The ECU 794 will estimate engine coolant tempera ture Check cabling between con trol unit and component Check the sen sor D794 ENGINE menu 7 110 3 P110 3 Engine Coolant Tempera ture 1 Sens...

Страница 728: ...erately Severe Level Engine coolant temperature signal indicates engine cool ant temperature is above en gine protection warning limit Progressive power derate increasing in severity from time of aler...

Страница 729: ...ail fuel is higher than the commanded pressure None or possible engine noise asso ciated with higher injection pressures especially at idle or light load Engine power is reduced D794 157 2 P157 2 Inje...

Страница 730: ...ed until very low battery voltage condition is correct ed Check batter ies and alterna tor D794 167 16 P167 0 Electrical Charging System Voltage High Data Valid but Above Normal Opera tional Range Mod...

Страница 731: ...ngine protection limit Fuel injection disa bled until engine speed fails below the overspeed limit Ease off throt tle or select higher gear 190 2 P190 2 Engine Crankshaft Speed Position Data Erratic I...

Страница 732: ...ponent Check the sen sor D794 558 2 S230 2 Accelerator Pedal or Lever Idle Validation Circuit Data Erratic Intermittent or Incor rect Voltage detected simul taneously on both idle validation and off i...

Страница 733: ...peed sensor Possible hard start ing and rough run ning D794 611 4 S232 4 Sensor Supply Voltage 4 Circuit Voltage Below Nor mal or Shorted to Low Source Low voltage detect ed at 5 VDC sensor supply cir...

Страница 734: ...s after key OFF Possible no notice able performance effects or engine dying or hard start ing Fault informa tion trip information and maintenance moni tor data can be in accurate Check fuses Check bat...

Страница 735: ...S018 11 Fueling Actuator Number 1 Circuit Error Conditions Ex ists Fuel pump actuator cir cuit resistance too high or too low Possible low power D794 639 9 S231 9 SAE J1939 Multiplexing PGN Timeout Er...

Страница 736: ...Check compo nent 647 3 S033 3 Fan Control Circuit Voltage Above Normal or Shorted to High Source Open circuit or high voltage detected at the fan control circuit The fan may stay on continuously or n...

Страница 737: ...Check cabling between con trol unit and component Check the in jector D794 653 5 S003 5 Injector Solenoid Driver Cyl inder 3 Circuit Current Be low Normal or Open Circuit High resistance or no cur re...

Страница 738: ...ween con trol unit and component Check the in jector D794 656 5 S006 5 Injector Solenoid Driver Cyl inder 6 Circuit Current Be low Normal or Open Circuit High resistance or no cur rent detected at Num...

Страница 739: ...rcuit Can not control transmission D794 703 11 S051 11 Auxiliary Equipment Sensor Input 3 OEM Switch Root Cause Not Known Possible engine power derate Check cabling between con trol unit and component...

Страница 740: ...794 974 3 P974 3 Remote Accelerator Pedal or Lever Position Sensor 1 Circuit Voltage Above Nor mal or shorted to High Source High voltage detect ed at remote accelerator pedal position circuit Remote...

Страница 741: ...Normal or Shorted to Low Source Low voltage detected on the ECU 794 voltage supply line to engine speed sensor Possible hard start ing and rough run ning Check cabling between con trol unit and compo...

Страница 742: ...Voltage Above Normal or Shorted to High Source High voltage or open detected at the fuel lift pump signal circuit Engine can be diffi cult to start D794 1075 4 S126 4 Electric Lift Pump for Engine Fue...

Страница 743: ...OFF switch have dif ferent values in the ECU 794 Multi Unit synchro nization feature is disabled D794 1172 3 3 Turbocharger Number 1 Compressor Inlet Tempera ture Sensor Circuit Voltage Above Normal...

Страница 744: ...run or possible low power D794 1378 31 S153 11 Change Lubricating Oil and Filter Condition Exists Change engine oil and filter None on perform ance maintenance reminder only D794 1388 3 P223 3 Auxilia...

Страница 745: ...4 5 3 6 PID94 5 Sensor fuel pres sure short circuitedtoground or open circuit No limitation Check cabling be tween control unit and component Check the sensor D794 B 16 94 7 3 8 PID94 7 Sensor fuel pr...

Страница 746: ...own Check that the charge air cooler is clean Check the sensor EN GINE menu 7 105 4 3 2 PID105 4 Sensor charge air temperature ca ble short circuited to ground No limitation Check cabling be tween con...

Страница 747: ...omponent Check the sensor D794 A 29 EN GINE menu 6 110 0 6 1 PID110 0 High coolant tem perature No limitation Check coolant level Check that radiator is clean Check thermostat Check the cap on the exp...

Страница 748: ...control unit and component Check the sensor D794 B 16 190 0 2 6 PID190 0 Engine rpm too high No limitation Ease off throttle or se lect higher gear 626 3 5 4 PID45 3 Preheating relay short circuited...

Страница 749: ...D794 A 45 A 46 636 8 2 5 SID21 8 Sensor engine rpm camshaft abnormal fre quency Engine takes longer time to start than normal Engine runs nor mally when it has started Check cabling be tween control u...

Страница 750: ...he engine Re program the con trol unit 639 9 1675 9 6 4 PSID201 9 Communication error with Engine control unit D794 configura tion error Instruments and controls do not work Use diagnostic menu to fin...

Страница 751: ...heck cylin der 1 D794 A 24 651 12 7 1 SID1 12 Electric failure in jector cylinder 1 Engine runs on 5 cylinders sounds rough and has re duced power Check cabling be tween control unit and component Che...

Страница 752: ...d power Check cabling be tween control unit and component Check the injector D794 A 32 653 4 7 3 SID3 4 Electric failure in jector cylinder 3 Engine runs on 5 cylinders sounds rough and has re duced p...

Страница 753: ...t and component Check the injector D794 A 56 654 7 7 4 SID4 7 Incorrect com pression or defec tive injector cylinder 4 Runs rough at low rpms and low load Check fuel pressure Check valve clear ance Ch...

Страница 754: ...5 Engine runs on 5 cylinders sounds rough and has re duced power Check cabling be tween control unit and component Check the injector D794 A 48 656 3 7 6 SID6 3 Electric failure in jector cylinder 6...

Страница 755: ...n Check cabling be tween control unit and component Check the relay D794 B 29 EN GINE menu 5 677 4 1675 4 6 3 SID39 4 Starter motor re lay short circuited to ground The engine will not start Check cab...

Страница 756: ...d engine power Check cabling be tween control unit and component Check the component 679 14 PSID97 14 Pressure relief valve defective component Engine speed limited to 1100 rpm Reduced engine power Ch...

Страница 757: ...nsor D794 A 7 1080 4 SID 211 4 Referencevoltage 5 V no 2 to sen sor short circuited to ground No limitation Check cabling be tween control unit and component Check the sensor D794 A 7 1239 0 PSID 96 0...

Страница 758: ...794 B 30 2791 4 PPID19 4 Internal EGR short circuited to ground Internal EGR not working Check cabling be tween control unit and component Check the component D794 B 30 2791 5 PPID19 5 Internal EGR op...

Страница 759: ...d limited to 1100 rpm High engine pow er Powerful en gine Check fuel feed PPID 435 4 Low fuel pressure Engine speed limited to 1100 rpm Reduced engine power Check fuel filter re place if necessary Che...

Страница 760: ...wn 00 51 Memory error in con trol unit transmission Transmission locked in neutral shutdown 00 52 Memory error in con trol unit transmission Transmission locked in neutral shutdown 00 53 Memory error...

Страница 761: ...ng to gear se lector with regards to for ward and reverse signal TRANSM menu 2 41 06 Incorrect gear selec tion from gear selec tor Control unit doesn t allow change of range however operation of machi...

Страница 762: ...for ac celerator pedal posi tion from engine control unit D794 Use diagnostic menu to find incorrect segment CAN POWER menu 4 46 05 Max torque for inch ing has been exceed ed 50 00 Sensor oil pressure...

Страница 763: ...The control unit limits the transmission s tempera ture measurement to the highest value in its set tings which results in poor temperature compensa tion Check cabling between control unit and compo n...

Страница 764: ...heck cable between con trol unit and component Check component D793 D3 B758 TRANSM menu 6 61 01 Sensor rpm output shaft B758 not con nected When only one rpm signal that is not the engine rpm signal i...

Страница 765: ...ck component D793 R2 B751 TRANSM menu 6 63 01 Sensor rpm turbine B751 not connect ed When only one rpm signal that is not the engine rpm signal is incorrect the con trol unit calculates the missing rp...

Страница 766: ...valve VFS 2 4 Y6069 open cir cuit or short circuited voltage Transmission in limp home Check cabling between control unit and compo nent Check the solenoid valve D793 D1 Y6069 E1 Y6069 TRANSM menu 8 7...

Страница 767: ...g between control unit and compo nent Check the solenoid valve D793 H1 Y6067 J1 Y6067 TRANSM menu 8 73 01 Solenoid valve VFS 1 3 Y6067 open cir cuit or short circuited voltage Transmission in limp hom...

Страница 768: ...mp home Check cabling between control unit and component Check the solenoid valve D793 F2 Y6075 TRANSM menu 7 82 01 Solenoid valve VSF 1 3 Y6075 cable is not connected or short circuited to voltage Tr...

Страница 769: ...orrect segment Varies depend ing on machine configuration CAN POWER menu 1 3 11 6 2 Re dundant CAN bus 12 Error in cable CAN network segment 2 Use diagnostic menu to find incorrect segment Varies depe...

Страница 770: ...Volvo D790 1 K13 1 K13 2 D794 2 1 Cummins D790 1 K13 1 K13 2 D794 46 37 CAN POWER menu 4 11 6 3 CAN bus drivetrain 23 Setup file cannot be read in cab control unit D790 1 No controls working in cab Co...

Страница 771: ...e re leased Check cabling between the control unit and the component with diag nostic menu Check the switch D791 1 K8 5 S107 7 D791 1 K8 13 S107 1 HYD menu 5 4 5 Parking brake 35 Interference during s...

Страница 772: ...uit or open circuit in cir cuit for fan motor M657 Cab fan not working Check cabling between the control unit and the component with diag nostic menu Check the motor D790 1 K2 2 M657 2 CLIMATE menu 6...

Страница 773: ...nsistor has been triggered due to short circuit or open circuit in cir cuit for roof and rear washer motor M651 2 Windshield washer rear and roof not working Check cabling between the control unit and...

Страница 774: ...nent with diag nostic menu Check the component D790 1 K7 10 K3005 86 EXT AT TACH menu 6 7 9 2 Twist locks 59 Transistor has been triggered due to short circuit or open circuit in cir cuit for relay fo...

Страница 775: ...units Check cabling between the control unit and the component with diag nostic menu Check the component D790 1 K10 12 K3009 2 86 CAN POWER menu 6 11 5 1 4 Emergency stop switch voltage 66 Transistor...

Страница 776: ...component CAN POWER menu 5 11 5 1 3 Igni tion voltage 80 No signal from Pressure switch air conditioning S246 despite the AC compressor be ing activated Air condition ing not work ing Check drive belt...

Страница 777: ...r 4 8 V Tilt not work ing Check cabling between the control unit and the component with diag nostic menu Check the lever D790 1 K7 4 R8072 3 ELSERV menu 1 P2 7 1 1 Control lever 89 Faulty signal from...

Страница 778: ...steering or mini wheel not working Check cabling between the control unit and the component with diag nostic menu Check the switch D790 1 K9 8 R825 1 H1 EL STEER ING menu 1 5 1 2 Mini wheel 5 1 3 Joys...

Страница 779: ...cab tem perature 97 Faulty signal from outdoor tempera ture sensor B774 Temperature signal over 105 C Air condition ing not work ing Check cabling between the control unit and the component with diag...

Страница 780: ...o feed All hy draulic func tions blocked Check fuse F58 2 1 and replace if necessary Check the wiring be tween the control unit and component with the diagnostic menu Check component D797 1 K2 11 F58...

Страница 781: ...with diag nostic menu D797 1 K1 28 E400L E400R LIGHTS menu 3 9 6 1 Head lights 111 Transistor has been triggered due to short circuit or open circuit in cir cuit for running lights H416 1 H416 2 H417...

Страница 782: ...r open circuit in cir cuit for solenoid valve lift mast Y6005 1 and so lenoid valve lower mast Y6004 1 Mast lifting lowering not working Check cabling between the control unit and the component with d...

Страница 783: ...freelift 115 Transistor has been triggered due to short circuit or open circuit in cir cuit for left direction indicator H422 H426 Left direction indicator not working Check bulb Check the lamp holde...

Страница 784: ...IGHTS menu 8 9 6 4 Brake lights 121 Transistor has been triggered due to short circuit or open circuit in cir cuit for reversing warning device H965 Back up alarm not working Check cabling between the...

Страница 785: ...Faulty signal from hydraulic pressure sensor for lift cylin der B768 1 Scales re generation and slack chain logic not working Overload sys tem not work ing Error code 150 acti vated Check the sensor...

Страница 786: ...solenoid valve for lift mast Y6005 1 Return current does not match control current Lift mast not working Check cabling between the control unit and the component with diag nostic menu Check the solen...

Страница 787: ...mast low ering Y6076 Re turn current does not match control current Lower mast not working Check cabling between the control unit and the component with diag nostic menu Check the solenoid valve D797...

Страница 788: ...id valve for lower carriage Y6004 2 Return current does not match control cur rent Lower not working Check cabling between the control unit and the component with diag nostic menu Check the solenoid v...

Страница 789: ...e ment Y6062 Quick lift pump en gagement not working Check cabling between the control unit and the component with diag nostic menu Check the solenoid valve D797 1 K1 35 Y6062 1 HYD menu 6 10 4 2 Axia...

Страница 790: ...ure sensor B776 Incorrect tem perature dis play Check the sensor Check cabling between the control unit and the component with diag nostic menu D797 1 K2 13 B776 1 HYD menu 1 10 6 4 Sen sor hydraulic...

Страница 791: ...eded Check cabling between the control unit and the component with diag nostic menu D797 F K2 11 F58 3 5 1 CAN POWER menu 13 11 5 1 4 Emergency stop switch voltage 155 Incorrect 5 V refer ence voltage...

Страница 792: ...tween the control unit and the component with diag nostic menu Check the solenoid valve D797 2 K1 3 Y636 4 1 EL STEER ING menu 4 5 2 10 Con trol valve joy stick steering mini wheel 163 Transistor has...

Страница 793: ...ve load handling 169 Reversible opera tor s seat Transistor has been triggered due to short circuit or open circuit in cir cuit for reversible driver s seat sensor S720 F S720 R Driver s seat position...

Страница 794: ...it or open circuit in cir cuit for solenoid valve cab sliding Y6080 Cab sliding not working Check cabling between the control unit and the component with diag nostic menu Check the solenoid valve D797...

Страница 795: ...Joystick steering or mini wheel not working Check cabling between the control unit and the component with diag nostic menu Check the solenoid valve D797 2 K1 16 Y636 3 2 Y636 4 2 AUXILIA RY EL STEER...

Страница 796: ...the control unit and the component with diag nostic menu D797 1 K1 37 H410L 1 VBFS menu 8 9 6 4 Brake lights 251 Redundant voltage feed left to frame control unit D791 1 does not reach destination Che...

Страница 797: ...tion M693 2 Central lubri cation attach ment not working Check cabling between the control unit and the component with diag nostic menu Check the component D791 1 K1 14 M693 2 1 OPT menu 2 9 14 1 Pump...

Страница 798: ...t in cir cuit for control valve for levelling clockwise Y637 1 Y637 2 Levelling of attachment not working Check cabling between the control unit and the component with diag nostic menu Check the solen...

Страница 799: ...nu Check the solenoid valve D791 1 K1 16 Y6018L 2 ATTACH menu 17 7 3 2 Control valve attach ment 263 DCF360 450CSG Transistor has been triggered due to short circuit or open circuit in cir cuit for so...

Страница 800: ...h diag nostic menu Check the solenoid valve D791 1 K1 17 Y6018R 2 ATTACH menu 19 7 3 2 Control valve attach ment 265 DCF360 450CSG Transistor has been triggered due to short circuit or open circuit in...

Страница 801: ...side shift left Y6020 Side shift left of attachment not working Check cabling between the control unit and the component with diag nostic menu Check the solenoid valve DCF360 450CSG D791 1 K1 32 Y6020...

Страница 802: ...CAN POWER menu 16 7 9 1 2 Con trol valve at tachment Transistor has been triggered due to short circuit or open circuit in cir cuit for voltage feed to attachment sen sor Sensor on at tachment not wor...

Страница 803: ...ndicator light H564 Indicatorlight attachment alignment not working Check bulb Check the lamp holder Check cabling between the control unit and the component with diag nostic menu D791 1 K1 39 H564 1...

Страница 804: ...valve spreading right out Y6018R Return current does not match control current Spreading right not work ing Check cabling between the control unit and the component with diag nostic menu Check the sol...

Страница 805: ...mponent with diag nostic menu Check the solenoid valve D791 1 K1 34 Y6018 1 ATTACH menu 13 7 5 2 Control valve attach ment Transistor has been triggered due to short circuit or open circuit in cir cui...

Страница 806: ...D795 K1 7 CAN POWER menu 9 11 5 1 2 Re dundant volt age feed of control units 452 Redundant voltage feed right to KID control unit D795 does not reach destination Check cabling between the control uni...

Страница 807: ...ics mm mm mm mm mm mm Table of Contents E Schematics 10 Common hydraulics 3 Hydraulic diagrams compilation 3 Hydraulic diagram DCF 90 100 electric servo 4 11 Common electrics 6 Circuit diagram descrip...

Страница 808: ...VDCF03 01GB Workshop Manual DCF 90 100 2 ESchematics...

Страница 809: ...Manual DCF 90 100 E Schematics 10 Common hydraulics 3 mm mm mm mm mm mm 10 Common hydraulics page Hydraulic diagrams compilation Designation Drawing number Hydraulic diagram DCF 90 100 electric servo...

Страница 810: ...ematics 10 Common hydraulics page Hydraulic diagram DCF 90 100 electric servo 1 2 3 4 4a 4b 4c 4d 4e 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 25 25 26 27 28 29 30 31 32 33 34 35 36...

Страница 811: ...valve for lift mast Y6005 and lower mast Y6004 tilt in Y6011 and tilt out Y6010 14 Cab tilt cylinder 15 Control valve for cab tilt control valve for cab tilt up Y6047 and cab tilt down Y6048 16 Accumu...

Страница 812: ...nent of this type in the specific diagram Sensors etc are drawn in resting position on circuit that is with out voltage Colour cables White cable ground signal Grey cable other cables Fuse box for exa...

Страница 813: ...rnator power supply device Example fuse H Signal device Example indicator light K Relay connector L Inductance reactance M Motor Example electric motor N Analogue element Example operation amplifier P...

Страница 814: ...M11 engine 1 0 2C Circuit Volvo 950 1240 1250 engine 1 0 2D Circuit Volvo TAD760 engine 1 0 2E1 Circuit Cummins QSB6 7 engine 1 0 2E2 Circuit Cummins QSB6 7 engine 2 0 1 Circuit drivetrain gearbox 2 0...

Страница 815: ...ck 7 9 2 Circuit sensor gantry 7 9 3 Circuit pliers Avesta 7 10 1 Circuit 5th function electric servo 7 10 2 Circuit option gantry 8 2 1 Circuit bypassing 8 2 2 Circuit overload system 8 2 3 Circuit m...

Страница 816: ...option hood lamp 9 6 14 Circuit work lights option carriage 9 7 1 Circuit alarm audible signals 9 7 2 Circuit back up alarm 9 7 3 Circuit compressor horn 9 7 4 Circuit for horn servo panel 9 8 1 Circu...

Страница 817: ...ircuit CAN bus KDU opt Sheet Designation Sheet Designation 0 0_1 Crossreference list 7 4_1 Circuit side shift 7 5_1 Circuit spreading 7 5_2 Circuit spreading buzzer 7 5_3 Circuit spreading sensors 7 8...

Страница 818: ...VDCF03 01GB Workshop Manual DCF 90 100 12 E Schematics 11 Common electrics...

Страница 819: ...ars obe h rigen anv ndas vertr delse h rav beivras med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third par...

Страница 820: ...CELERATOR 0V reference POT ACCELERATOR Analog reference 5V OVERRIDE ALIGNMENT Input K10 3 LAMP INST ILLUMINATION PWM SW W LIGHTS CARRIAGE Input SW WORK LIGHTS MAST Input SWITCH ROT BEACON Input SWITCH...

Страница 821: ...E1 7 0_7 C8 2 0_1 C8 9 6_5 B1 9 4_2 F1 9 6_7 E1 9 6_7 D1 1 0_1 F1 9 6_6 D1 4 0_1 E1 10 4_1 D2 8 2_3 C1 8 2_3 C8 10 4_1 C2 9 4_1 A8 4 0_1 C8 9 0_1 C2 6A 1 5A 1 5A 1 5A 1 5A 0V Ref 1 5A Analog Ref 5V 1...

Страница 822: ...11 5_10 A1 9 3_6 B1 9 3_6 C1 11 5_11 B1 11 5_11 C1 9 3_3 C8 11 5_9 A1 9 3_5 B1 5 2_2 B8 7 10_1 B8 7 4_1 B8 7 5_1 E8 9 3_3 D8 11 5_10 B8 11 5_10 B8 11 5_10 C8 11 5_9 C1 9 3_5 D1 11 5_11 D1 11 5_9 B1 9...

Страница 823: ...6_2 D2 7 3_1 B7 7 3_1 C7 7 4_2 B7 7 5_2 B7 7 5_2 E7 7 10_2 B7 7 9_2 D8 7 9_2 E8 7 9_2 B8 7 9_1 C2 7 9_2 C8 7 9_2 E8 7 5_3 D1 7 9_1 D2 7 8_1 B2 7 8_1 A2 7 4_2 B2 7 4_2 C2 7 5_2 B2 7 5_2 C2 7 10_2 C2 7...

Страница 824: ...the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Proje...

Страница 825: ..._2C C2 1 0_2D B2 1 0_2E2 B2 58 2 7 1 1 0_2A B2 1 0_2B1 B1 1 0_2C C2 1 0_2D B2 1 0_2E1 F1 CAN_J1939_ 1 0_2B1 B1 1 0_2C C2 1 0_2D B2 58 1 3 1 1 2 B690 1 ACCELERATOR 3 X690 1f 1 X690 1f 2 3 X038f 5 X006...

Страница 826: ...ted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets motor TAD 722 Wiring engine TAD722 DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 0...

Страница 827: ...roduct 5 Huvudnr Project no A49226 0100 15 Krets motor Cummins QSM11 Wiring engine Cummins QSM11 DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 1 0_2B1 A47137 010...

Страница 828: ...r written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produk...

Страница 829: ...o a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets motor 950 1240 1...

Страница 830: ...uct 5 Huvudnr Project no A49226 0100 15 Krets motor TAD760 Wiring engine TAD760 DCF300 DCE300 6 CJS 051123 CJS 061220 1 Preheat added 071438 CJS 070923 1 0_2D A47137 0100 X210m 1 2 3 4 6 7 8 G D B G66...

Страница 831: ...070123 1 New page 071438 CJS 070923 1 0_2E1 A47137 0100 X210m 3 4 X210m 6 8 X278m 2 1 0_1 F6 START XD794 2m 1 50 2 50 3 50 4 50 5 50 6 50 7 50 8 50 9 50 10 50 11 50 12 50 13 50 14 50 15 50 16 50 17 5...

Страница 832: ...pied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Bl...

Страница 833: ...utch XS220 3 added 071438 CJS 070923 2 0_1 A47137 0100 9 1_1 C2 790 1 5 1 24V 9 6_5 E2 58 2 5 1 4 0_1 C2 58 2 5 1 R S162 MULTI SWITCH 9 5_1 B4 9 6_4 D4 F N R F N 15 1 GEAR X006 14 X038f 2 X038f 1 X211...

Страница 834: ...r be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets v xell da TE32 Wiring gearbox TE32...

Страница 835: ...0100 15 Krets v xell da TE32 Wiring gearbox TE32 DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 2 0_2A2 A47137 0100 B752 DRUM SPEED 1 2 B758 OUTPUT SPEED 1 2 B751...

Страница 836: ...udnr Project no A49226 0100 15 Krets v xell da TE32 Wiring gearbox TE32 DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ventil Y602 utg r 071438 CJS 070923 2 0_2A3 A47137 0100 1 2 Y6069 VFS 2ND 4TH 1 2 Y630 V...

Страница 837: ...nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets v xell da TE17 Wiring gearbox TE...

Страница 838: ...070923 2 0_2B2 A47137 0100 D793 DRUM SPEED RPM B3 D793 OUTPUT SPEED RPM D3 X251f B3 X251f D3 B752 DRUM SPEED 1 2 B758 OUTPUT SPEED 1 2 XB752f 1 2 XB758f 1 2 X251f C3 X251f E3 D793 DRUM SPEED RPM C3 D...

Страница 839: ...B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets v xell da TE17 Wiring gearbox TE17 DCF300 DCE300 6 CJS 061129 CJS 061220 1 New page 071438 CJS 070923 2 0_2B3 A47137 0100...

Страница 840: ...DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets Bromssystem Wiring brake system DCF300 DCE300 6 CJS 050128 CJS 061220 1 X211 34 V X211 39 071438 CJS 070923...

Страница 841: ...se Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets kyln bromsl olja Wiring cooling brake oil DCF300 DCE300 6 CJS 050128 C...

Страница 842: ...NGLE BN BK BU X018 2 X018 3 X018 1 X009Am 7 X009Af 7 1 2 R825 1 MICRO STEERING P6 3 1 2 R825 2 MICRO STEERING P7 3 X009Am 8 X009Am 6 X009Am 9 X009Af 6 X009Af 8 X009Af 9 0 0_1 B6 D790 1 SWITCH HORN ARM...

Страница 843: ...reof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 010...

Страница 844: ...XTRA P5 LEVELLING 3 X007 2 XR8073f 1 XR8074f 1 XR8075 1f 1 2 2 2 X007 1 X007 3 X007 4 X007 5 X007 6 X007 7 X090f 3 X090m 3 1 2 R8075 2 EXTRA P7 PROJECTION RIGHT 3 XR8075 2m 3 2 XR8075 2m 1 XR8075 2f 1...

Страница 845: ...4 11 1 10 7 15 5 9 X815f 15 7 6 9 10 X815f 14 16 20 19 17 18 8 4 11 1 X090f 2 X090m 2 D790 1 POTENTIOM EL SERVO Analog Reference 5V K7 2 X007f 2 D790 1 POT P4 Analog Input K7 6 D790 1 POT P3 Analog In...

Страница 846: ...Huvudnr Project no A49226 0100 15 Krets tillbeh rsaggregat Wiring toplift frame DCF300 DCE300 6 CJS 050128 CJS 061220 1 Flyttad fr n 9 1_3 071438 CJS 070923 7 0_4 A47137 0100 7 0_5 E2 Alignment 7 0_5...

Страница 847: ...CJS 070923 7 0_5 A47137 0100 7 0_4 B7 Alignment 7 0_4 C7 Unlock TW 7 0_4 D7 Lock TW 11 5_6 D7 58 3 3 1 X202f 1 X202f 5 X202f 6 X202f 7 X202f 2 X202f 4 X202f 3 9 7_2 C7 CHASSIS 30 87 TWISTLOCK 30 87 SP...

Страница 848: ...e copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E...

Страница 849: ...nts thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49...

Страница 850: ...E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets frilyft sensorer Wiring free lift sensors DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 C...

Страница 851: ...ithout our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad She...

Страница 852: ...RAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets ventiler stativ Wiring control valves mast DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New desig...

Страница 853: ...secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets aggregat gantry Wiring projection gantry DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion Ne...

Страница 854: ...on and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudn...

Страница 855: ...copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F...

Страница 856: ...tion New design 071438 CJS 070923 7 5_1 A47137 0100 9 7_4 B2 24V D790 1 8 16 9 1_1 A2 CHASSIS 37 D 9 1_1 A2 24V D790 1 8 16 7 9_1 A2 CHASSIS 37 D X008 10 10 1 9 1 10 5 3 7 0 1 5 10 1 7 9 S1004 CAB 30...

Страница 857: ...A49226 0100 15 Krets spridning gantry Wiring spreading gantry DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 7 5_2 A47137 0100 X90053 1 2 Y6018 SPREADING OUT 1 2...

Страница 858: ...ust not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 K...

Страница 859: ...and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr...

Страница 860: ...ment must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING...

Страница 861: ...dukt Product 5 Huvudnr Project no A49226 0100 15 Krets skevning gantry Wiring levelling gantry DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 7 8_1 A47137 0100 1...

Страница 862: ...istlock 1 2 H562 UNLOCKED TW 1 2 H563 LOCKED TW 1 2 H564 ALIGNMENT XH562 1 1 XH562 2 1 XH564 1 1 XH563 1 1 XH563 2 1 XH564 2 1 1 2 Y6039 UNLOCK TW 1 2 Y6040 LOCK TW 1 2 1 2 X421 25 X421 29 X421 39 X42...

Страница 863: ...B XB7202Lf A XB7204Lf C B XB7204Lf A XB7205Lf C B XB7205Lf A XB7203Lf C B XB7203Lf A X403Bf 1 X403Bm 1 X90054 7 5_2 D1 24V D791 1 1 10 X90055 7 5_2 D6 CHASSIS 2 2 X403Bf 3 X403Bm 3 X403Bm 4 X403Bf 4 X...

Страница 864: ...G R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets t ng Avesta Wiring attachment Avesta DCF300 DCE300 6 CJS 050128 CJS 061220 1 Connection attachment Avesta changed...

Страница 865: ...n and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr...

Страница 866: ...unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets option gantry Wiring option gantry DCF300 DCE300 6...

Страница 867: ...med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contrav...

Страница 868: ...y nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets verlastsystem Wiring overloadi...

Страница 869: ...ission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Hu...

Страница 870: ...ed for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets RMI Wiring RMI DCF300 DCE300 6 CJS 060529...

Страница 871: ...as med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Cont...

Страница 872: ...CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 9 1_1 A47137 0100 2 0_1 C2 790 1 5 1 24V 9 1_2 B7 CHASSIS 9 1 5 10 X005 1 X006 9 X080f 9 X081f 1 X081f 2 X080m 9 X081m 1 X081m 2 0...

Страница 873: ...d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention...

Страница 874: ...DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets Stolsv rme Wiring seat heater DCF300 DCE300 6 CJS 050128 CJS 061220 1 XE803f and XE803m changed place 07143...

Страница 875: ...our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Pro...

Страница 876: ...90 1 8 16 S720 F SEAT POS FRONT BU BK BN BK WH S720 R SEAT POS REAR BU BK BN BK WH X690 2f 1 X690 2f 2 3 X221 13 X221 20 X221 7 9 1 10 7 3 X008 15 1 2 3 1 0_1 A4 5V 1 0_1 A6 0V X243f 4 X243m 4 X245m 1...

Страница 877: ...d the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Pro...

Страница 878: ...100 15 Krets v ndbar f rarstol Wiring turnable drivers seat DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 9 3_5 A47137 0100 1 2 E401R DIPPED LIGHT REAR RIGHT 1 2...

Страница 879: ...on and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudn...

Страница 880: ...roject no A49226 0100 15 Krets v ndbar f rarstol Wiring turnable drivers seat DCF300 DCE300 6 CJS 060124 CJS 061220 1 Cable BN and BU switched in A798 071438 CJS 070923 9 3_7 A47137 0100 0 0_3 D5 D797...

Страница 881: ...004 9 X004 11 X035f 7 X035f 8 X036f 8 X004 12 X035f 9 X036f 9 4 X033m 1 X033m 5 X033m 2 X033m 3 X035m 7 X035m 8 X036m 8 X035m 9 X036m 9 XS246 2 1 9 6_5 E2 58 2 5 1 XS246 1 1 X065m 1 X065f 1 X039f 9 X0...

Страница 882: ...34f 7 X034f 9 X034f 8 X039f 8 X010 4 X039f 6 X034f 1 X034f 2 X039f 5 X036f 1 X036f 2 X035m 2 X035m 1 X035m 4 X035m 6 X035m 5 X034m 5 X034m 4 X034m 7 X034m 9 X034m 8 X039m 8 X039m 6 X034m 1 X034m 2 X03...

Страница 883: ...1m 3 XM650 1m 4 X057m 1 X057f 1 X057m 3 X057f 3 X057m 4 X057f 4 X057f 2 X057m 2 X37 B XM650 3m 4 XM650 3f 4 X055f 3 X055m 3 X055f 1 X055m 1 X055f 2 X055f 4 X055m 2 X055m 4 XM650 3f 2 XM650 3m 2 X058f...

Страница 884: ...1 A47137 0100 9 6_2 B2 790 1 5 1 24V X080f 1 X006 10 9 1 5 10 X080m 1 0 1 5 10 1 9 S105 1 WORK LIGHTS 20 40 9 6_2 B2 CHASSIS X010 8 X007 8 K3017 1 85 86 K3017 2 85 86 85 87 30 86 86 30 87 85 11 5_2 B6...

Страница 885: ...eet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets arbetsljus vagn Wiring work lights carriage DCF300 DCE300 6 CJS 050128 CJS 061220 1 Extra worklight added 071438 CJS 070923 9 6_2 A47137 0...

Страница 886: ...pose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets arbetsljus stativ Wiring work lights mast DCF300 DCE300 6 CJS 050128...

Страница 887: ...heet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets belysning Wiring lights DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 9 6_4 A47137 0100 56b 56a 56...

Страница 888: ...D LIGHT FRONT RIGHT 1 2 H416 1 SIDE POSITION FRONT LEFT 1 2 H417 1 SIDE POSITION FRONT RIGHT X90006 11 5_1 B8 58 2 5 1 2 0_1 C2 58 2 5 1 1 1 X270f 2 X271f 2 1 1 X211 28 X211 15 X270f 1 X271f 1 X211 2...

Страница 889: ...R LEFT 1 2 H411R BRAKE LIGHT REAR RIGHT 1 2 H412L REAR LIGHT LEFT 1 2 H412R REAR LIGHT RIGHT 1 2 H416 2 SIDE POSITION REAR LEFT 1 2 H417 2 SIDE POSITION REAR RIGHT X90007 1 2 E405L REVERSING LIGHT REA...

Страница 890: ...rection Left Rear 1 2 H423 Direction Right Front 1 2 H422 Direction Left Front X90003 R 0 L 1 2 3 4 5 6 S161 DIRECTION LIGHT 9 6_6 E7 CHASSIS 9 6_6 D7 CHASSIS 9 6_5 D7 CHASSIS 9 6_5 C7 CHASSIS 9 3_5 D...

Страница 891: ...y konstruktion New design 071438 CJS 070923 9 6_8 A47137 0100 11 5_2 A6 58 4 2 1 11 5_3 C2 58 4 2 1 1 2 S266 LE BRAKING CAB DOOR 11 5_2 A6 58 4 2 1 1 2 S266 RI BRAKING CAB DOOR 1 2 E434 1 INTERIOR LIG...

Страница 892: ...s document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted D...

Страница 893: ...ocument must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAW...

Страница 894: ...contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project n...

Страница 895: ...5 Huvudnr Project no A49226 0100 15 Krets extra bel aggr Wiring work lights carriage opt DCF300 DCE300 6 CJS 050405 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 9 6_12 A47137 0100 XE404L...

Страница 896: ...0 15 Krets arbetsljus option lamphuv Wiring work lights option fenders DCF300 DCE300 6 CJS 060823 CJS 061220 1 New page 071438 CJS 070923 9 6_13 A47137 0100 11 5_1 C5 58 1 8 1 85 86 30 87 X270 271m 1...

Страница 897: ...imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets arbets...

Страница 898: ...d DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets larm ljudsignaler Wiring alarm buzzer and horn DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion Ne...

Страница 899: ...d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention...

Страница 900: ...nt must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R...

Страница 901: ...g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will...

Страница 902: ...pied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Bl...

Страница 903: ...d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention...

Страница 904: ...ur written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produ...

Страница 905: ...7 2 1 5A K1 39 D797 2 Input K1 13 D797 2 Input K1 20 B769 1 CAB TILT UP BN BK BU B769 2 CAB TILT DOWN BN BK BU X221 13 X221 20 X221 29 X221 39 X221 7 1 2 Y6047 CAB TILT UP RIGHT 1 2 Y6048 CAB TILT DOW...

Страница 906: ...ithout our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad She...

Страница 907: ...ut our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet P...

Страница 908: ...n permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Produc...

Страница 909: ...200C A 1 D 1 A 1 D 1 1 1 4 2 H 1 X37 100A X37 100B X071 2 X37 200 X37 200 X37 200 X37 100 X37 100 X37 100 M M654 30 50 31 STARTER 11 5_5 D2 58 2 3 1 11 5_5 D2 58 2 3 1 11 5_5 D2 58 2 3 2 3 2 11 5_10 B...

Страница 910: ...59f 5 3 4 3 1 1 1 2 1 2 2 5 1 6 1 8 1 5 1 3 1 1 2 1 1 2 1 4 1 6 1 7 1 8 1 3 2 X052f 6 X052m 6 X37 A 5 2 7 0_5 B1 58 4 5 2 1 X067f 2 3 X37 B 4 1 A 1 A 2 C 1 C 2 D 1 E 2 F 1 G 2 H 1 A 1 A 2 G 2 H 1 F 2...

Страница 911: ...0 15 Krets str m Wiring power DCF300 DCE300 6 CJS 050128 CJS 061220 1 K315 1 v K1 K315 2 v K4 071438 CJS 070923 11 5_3 A47137 0100 K315 1 MAIN RELAY IGNITION 85 86 11 5_1 A2 K315 2 RELAY IGNITION 85 8...

Страница 912: ...0100 15 Krets str m Wiring power DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 11 5_4 A47137 0100 11 5_1 A8 58 2 1 1 11 5_1 A8 58 2 1 1 11 5_1 B8 58 2 1 2 11 5_1...

Страница 913: ...d Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets str m Wiring power DCF300 DCE300 6 CJS 050128 CJS 061220 1 Ny konstruktion New design 071438 CJS 070923 11 5_5 A47137 0100 11 5_6 D7 5...

Страница 914: ...2 RELAY OPERATING SWITCH 85 86 11 5_6 D3 K3009 1 RELAY OPERATING SWITCH 85 86 11 5_6 D2 11 5_1 D3 54 3 11 5_3 D7 CHASSIS X052f 4 8 1 X051f 1 X011 13 A 1 X010 11 X010 12 X052f 5 X051m 1 X052m 5 X052m 4...

Страница 915: ...on and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudn...

Страница 916: ...gen anv ndas vertr delse h rav beivras med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be us...

Страница 917: ...on and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudn...

Страница 918: ...ed purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets option grund Wiring option base DCF300 DCE300 6 CJS 050128 CJS...

Страница 919: ...ird party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets option grund Wiring op...

Страница 920: ...2 3 X061m 3 X051m 2 5 X061Am 3 3 X051m 4 1 7 6 1 2 3 4 5 X203m 6 X052m 1 X052m 2 4 X049m A B 9 X060Am 5 6 2 3 1 4 X37 A 8 1 0_1 C3 CAN_J1939_ 1 0_1 D3 CAN_J1939_ 2 0_1 D2 CAN_J1939_ 2 0_1 D2 CAN_J193...

Страница 921: ...ied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Bla...

Страница 922: ...n and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr...

Страница 923: ...be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A49226 0100 15 Krets CAN BUS KDU opt Wiring CAN BUS KDU opt chassi attach DCF300 DCE300 6 CJS 050128 CJS 061220...

Страница 924: ..._1 B1 7 9_1 C1 11 5_2 A2 11 5_2 D2 7 5_3 B8 7 9_4 B8 9 14_1 B2 9 6_1 B1 7 5_1 A7 7 5_1 D7 7 4_1 B7 7 8_1 B7 7 5_3 B8 7 9_4 D8 7 9_2 A8 7 9_2 D8 7 9_2 D8 11 5_2 B2 7 9_4 E8 7 9_4 C8 7 5_2 B2 11 5_2 E2...

Страница 925: ...t not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B...

Страница 926: ...rized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A50400 0100 03 Krets spridning Wiring spreading DCF80 100 45E 6 CJS 050916 CJS 0...

Страница 927: ...h rav beivras med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized p...

Страница 928: ...CJS 050916 1 Changes after prototype 070572 CJS 070903 7 5_3 A51185 0100 B769L DAMPING 20 40 LEFT BN BK BU 0 0_1 C3 D791 SENSOR DAMPING LEFT Dig In 1 5A K1 12 11 5_2 A5 D791 1 10 24V B777L 30 35 STOP...

Страница 929: ...t be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D...

Страница 930: ...is document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted...

Страница 931: ...ER BN BK BU 0 0_1 C5 D791 SENSOR LOCKED LEFT LOWER Analog In 0 5V K1 23 0 0_1 C5 D791 SENSOR LOCKED RIGHT LOWER Analog In 0 5V K1 24 11 5_2 D5 D791 1 11 24V 11 5_2 D5 D791 1 36 24V XB7204Lm A XB7204Lm...

Страница 932: ...ied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Bla...

Страница 933: ...e contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project...

Страница 934: ...rty nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt Product 5 Huvudnr Project no A50400 0100 03 Krets sensorer anliggning Wiring s...

Страница 935: ...ritten permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad Sheet Produkt P...

Страница 936: ...hanges after prototype 070572 CJS 070903 7 9_5B A51185 0100 B7203LU DETECT LEFT UPPER BN BK BU B7203LL ALIGNMENT LEFT LOWER BN BK BU B7203RU DETECT RIGHT UPPER BN BK BU B7203RL ALIGNMENT RIGHT LOWER B...

Страница 937: ...Krets arbetsljus vagn aggregat Wiring work lights carriage attachment DCF80 100 45E 6 CJS 050916 CJS 050916 1 Changes after prototype 070572 CJS 070903 9 6_1 A51185 0100 0 0_1 C3 D791 WORK LIGHT LEFT...

Страница 938: ...eivras med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose...

Страница 939: ...d without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be pro secuted DRAWING R E A B C D E F Blad...

Страница 940: ...LOWER 1 5A K1 39 0 0_1 C5 D791 LAMP UNLOCKED 1 5A K1 25 0 0_1 D5 D791 LAMP ALIGNMENT UPPER 1 5A K1 34 0 0_1 C5 D791 LAMP LOCKED 1 5A K1 29 7 9_3A A2 7 9_3B B1 D791 1 25 24V 7 9_3B C1 D791 1 34 24V 7...

Страница 941: ...beivras med st d av g llande lag This document must not be copied without our written permission and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpos...

Страница 942: ......

Страница 943: ...1 S Str mst llare f nsterhiss Switch window regulator 112 S Str mst llare kylanl ggning AC Switch air conditioner AC 113 S Str mst llare styrning alt Switch alternative steering 114 S Str mst llare l...

Страница 944: ...g Switch pneumatic springing 168 S Str mst llare l sn stol Switch interlocking of seat 169 S Str mst llare stolsv ndning Switch reversible seat 170 S Str mst llare f r ngare LPG Switch evaporator LPG...

Страница 945: ...mpa l sning v ndskiva Contact warning interlocking of turntable 235 S Slutkontakt sidoskjutning stol Contact making side shifting of seat 236 S Slutkontakt vattenniv Contact water level 239 S Brytkont...

Страница 946: ...lashing hazard brake lights 327 K Rel v xel neutral Relay gear neutral 328 K Rel v xelskifte Relay gear shift 329 K Rel v xel h g l g Relay high low gear 330 K Rel startsp rr Relay start interlock 331...

Страница 947: ...rol 377 K Kontaktor bak reglersystem Contactor reversing operating control 378 K Kontaktor by pass reglersystem F ltf rsvagning Contactor by pass operating control Field weakening 379 K Kontaktor pump...

Страница 948: ...n lamp 429 E G lampa cigarett ndare belysning Light bulb cigarett lighter illumination 431 E G lampa instrument belysning Light bulb instrument illumination 432 E G lampa handsfack belysning Light bul...

Страница 949: ...Light bulb red extender exended 466 H G lampa orange vertikalh lning p Light bulb orange vertical hold on 467 H G lampa gr n kl mtryck OK Light bulb green clamp pressure OK 468 G Lampa R d Maxlast Lig...

Страница 950: ...amp position front legs 579 H Kontroll lampa kl ml ge bakre ben Indicator lamp clamp position rear legs 580 H Kontroll lampa fr mre ben uppe Indicator lamp front legs upper position 581 H Kontroll lam...

Страница 951: ...v ndskiva Solenoid valve fifth wheel locking 645 Y Magnetkoppling komp AC Magnetic clutch compressor AC 646 Y M ventil stolsv ndning Solenoid valve seat rotation 647 Y M ventil stolstilt Solenoid val...

Страница 952: ...ansmitter revolving driver s seat VBFS 740 D FleetManager kontrollenhet FleetManager control unit 741 U FleetManager batterifilter FleetManager battery filter 742 D FleetManager kortl sare FleetManage...

Страница 953: ...llenhet styrning Electronic Control Unit steering system 793 D Elektronisk kontrollenhet v xell da Electronic Control Unit gearbox 794 D Elektronisk kontrollenhet motor Electronic Control Unit engine...

Страница 954: ...s down 1007 S Str mst llare f llning bakre ben Switch rear legs down 1008 S Str mst llare kl mma lossa ben Switch clamping releasing legs 1009 S Str mst llare Motor information Switch Engine informati...

Страница 955: ...05 K Rel twist lock Relay twist lock 3006 K Rel spridning Relay spreading 3007 K Rel lyft s nk Relay lifting lowering 3008 K Rel hydraulfunktion extra Relay extra hydraulic function 3009 K Rel man ver...

Страница 956: ...lenoid valve rotation counter clockwise 6010 Y M ventil tilt ut Solenoid valve tilt out 6011 Y M ventil tilt in Solenoid valve tilt in 6012 Y M ventil tilt Solenoid valve tilt 6013 Y M ventil f llning...

Страница 957: ...ve regeneration left 6053 Y M ventil k rl ge Solenoid valve driving position 6054 Y M ventil kl mma ihop Solenoid valve clambing in 6055 Y M ventil kl mma is r Solenoid valve clambing out 6056 Y M ven...

Страница 958: ...kl m bakre ben Sensor Clamp rear legs 7217 S Givare fr mnre kn Sensor front knee 7218 S Givare bakre kn Sensor rear knee 7219 S Givare fr mre ben Sensor front legs 7220 S Givare bakre ben Sensor rear...

Страница 959: ...entiometer extender 8087 R Potentiometer kl mma Potentiometer clamp 8088 R Potentiometer skevning Potentiometer levelling 8089 R Potentiometer krokl sning Potentiometer flaps 8090 V Laser pappersaggre...

Страница 960: ......

Страница 961: ...ta and volume 3 Oils and lubricants recommendation 6 Tightening torques recommendations 8 Tightening torques ORFS couplings 9 Tightening torque climate control system connections 11 Unit explanations...

Страница 962: ...VDCF03 01GB Workshop Manual DCF 90 100 2 F Technical data...

Страница 963: ...1680 W 24 V 70 Ah Start battery voltage capacity 24 V 2x12 V 140 Ah 2 Transmission Dana Spicer Off Highway TE17 No of gears forward reverse 3 3 3 Driveline axle Drive axle type Kessler D81 Kessler D9...

Страница 964: ...ights 1 2 W2x4 6d Interior lighting 10 S8 5 Tail light 5 BA15s Brake light 21 BA15s Driving direction indicator 21 BA15s Running lights 5 W2 1x9 5d Headlights high and low beams 55 50 P43t 38 Reversin...

Страница 965: ...ystem 22 litres 29 litres 2 Transmission Dana TE17 Oil volume gearbox 37 litres during change 3 Driveline axle Kessler D81 Kessler D91 Differential 42 litres 54 litres Hub reduction 2x4 litres 9 Frame...

Страница 966: ...n with oil change The change interval for engine oils is conditional on the sulphur content in the fuel does not exceed 0 5 Engine oil that meets both VDS 2 and ACEA E5 may be used NOTE API CH 4 or CI...

Страница 967: ...valent If uncertain contact Kalmar Industries Coolant The coolant shall consist of clean water mixed with 40 60 glycol If glycol is not used then anti corrosion agent must always be added However anti...

Страница 968: ...ac cording to the table below State Bolt Nut Lubrication 1 untreated untreated oil 2 bright galvanized untreated or bright galvanized dry or oil 3 hot galvanized untreated dry or oil Quality 8 8 10 9...

Страница 969: ...136 Nm 173 Nm 216 Nm 255 Nm 5 8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm 3 4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm 7 8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm 1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm 1 1 8 1260 Nm 1...

Страница 970: ...htening torques mm inch Nm UNF UN Metric ISO BSSP Thread inch Tightening torques Nm Thread mm Tightening torques Nm Thread inch Tightening torques Nm 7 16 20 21 10x1 20 1 8 28 20 1 2 20 27 12x1 5 35 1...

Страница 971: ...age Unit explanations Hose diameter Thread Tightening torques mm inch inch Nm 6 1 4 7 16 7 14 Nm 10 3 8 5 8 14 20 Nm 10 3 8 11 16 14 20 Nm 12 1 2 3 4 14 27 Nm 16 5 8 7 8 27 41 Nm 19 3 4 1 1 16 34 47 N...

Страница 972: ...x 14 5 psi x 0 069 bar kp cm2 x 14 22 psi x 0 070 kp cm2 N mm2 x 145 04 psi x 0 069 bar MPa x 145 psi x 0 00689 MPa Power W J s kW x 1 36 hp cv x 0 736 kW kW x 1 34 bhp x 0 746 kW kW x 0 948 Btu s x 1...

Страница 973: ...0 1 1 mm 0 1 cm 1 mm 0 001 m Unit cm2 m2 km2 a ft2 yd2 in2 cm2 1 0 0001 0 000001 0 001076 0 000012 0 155000 m2 10000 1 0 000001 0 01 10 764 1 1958 1550 000 km2 1000000 1 10000 1076400 1195800 a 0 01 1...

Страница 974: ...3495 0 02835 0 000028 1 0 0625 lb 453 592 0 45359 0 000454 16 1 1ton metric 1 1023 ton US 0 9842 ton UK Unit kp cm2 bar Pa N m2 kPa lbf in2 lbf ft2 kp cm2 1 0 98067 98066 5 98 0665 14 2233 2048 16 ba...

Страница 975: ...VDCF03 01Gb Workshop Manual DCF 90 100 G Terminology and index 1 G Terminology and index mm mm mm mm mm mm Table of Contents G Terminology and index Terminology and index 3 Terminology 3 Index 6...

Страница 976: ...VDCF03 01Gb Workshop Manual DCF 90 100 2 G Terminology and index...

Страница 977: ...eller shaft and drive axle with differential and hub reduction Dust reservoir The air filter collects the coarsest particles in a dust reservoir which empties automati cally while driving ECC Electric...

Страница 978: ...e i e engine alternative Progressive steering Quick steering wheel movements give greater steering angle Proportional valve An electromagnetically controlled valve If a current is applied the valve is...

Страница 979: ...ding holes in container and twisted to lock the container when lifting Type designation Indicates machine type and capacity See also machine model Valve spool Movable part in valve Determines oil s pa...

Страница 980: ...ngine 1 6 Air pollution B Safety Air suspension 9 Frame body cab and accessories 9 3 5 Air vents 9 Frame body cab and accessories 9 4 15 Alternator 11 Common electrics 11 4 Alternator 11 Common electr...

Страница 981: ...Calibration 8 Control system 8 5 2 CAN bus drivetrain 11 Common electrics 11 6 3 CAN POWER 8 Control system 8 4 1 CAN bus 11 Common electrics 11 6 1 Central lubrication 9 Frame body cab and accessori...

Страница 982: ...8 2 Control valve lift and tilt 7 Load handling 7 2 5 Control valve lift and tilt 7 Load handling 7 7 5 Controls and instruments 1 Engine 1 1 Controls and instruments 2 Transmission 2 1 Controls and...

Страница 983: ...fety Electric protection 11 Common electrics 11 2 Electrical distribution 11 Common electrics 11 5 Electrical distribution box 11 Common electrics 11 5 2 ELSERV 8 Control system 8 4 8 Emergency stop s...

Страница 984: ...cessories 9 13 3 Foreword A Foreword Form for copying A Foreword Frame body cab and accessories 9 Frame body cab and accessories 9 Fresh air and recirculation damper 9 Frame body cab and accessories 9...

Страница 985: ...10 6 8 Hydraulic oil fine filter 10 Common hydraulics 10 6 9 Hydraulic oil pump 4 Brakes 4 3 1 Hydraulic oil pump 4 Brakes 4 5 1 Hydraulic oil pump 4 Brakes 4 8 3 Hydraulic oil pump 5 Steering 5 2 1...

Страница 986: ...valve 7 Load handling 7 7 6 Lubrication system 2 Transmission 2 6 Main beam side lifting attachment 7 Load handling 7 5 5 Mast 7 Load handling 7 2 9 Mast 7 Load handling 7 7 8 Mast position sensor 7...

Страница 987: ...Parking brake unit 4 Brakes 4 5 4 Passenger seat 9 Frame body cab and accessories 9 3 8 Pause heater 9 Frame body cab and accessories 9 4 19 Pipes and hoses 4 Brakes 4 3 10 Pipes and hoses 4 Brakes 4...

Страница 988: ...word Reading out error code D Error codes Reading lamp 9 Frame body cab and accessories 9 11 8 Rear window 9 Frame body cab and accessories 9 9 4 Rearview mirror 9 Frame body cab and accessories 9 9 5...

Страница 989: ...9 3 14 Sensor outdoor temperature 9 Frame body cab and accessories 9 4 18 Sensor temperature outlet fan 9 Frame body cab and accessories 9 4 16 Sensor temperature refrigerant 9 Frame body cab and acce...

Страница 990: ...tomatic spreading 7 Load handling 7 1 13 Switch direction indicators 9 Frame body cab and accessories 9 1 22 Switch lock twistlock lock tongue 7 Load handling 7 1 2 Switch spreading 20 40 7 Load handl...

Страница 991: ...ample 0 Complete machine Troubleshooting general work instructions 0 Complete machine Twistlocks 7 Load handling 7 9 1 Tyre and rim system 6 Suspension 6 3 Tyre and rim system B Safety Tyres 6 Suspens...

Страница 992: ...y cab and accessories 9 5 6 Wiper rear 9 Frame body cab and accessories 9 5 3 Wiper roof 9 Frame body cab and accessories 9 5 2 Wiper washer system 9 Frame body cab and accessories 9 5 Work lights att...

Отзывы:

Нет отзывов