Empty Container Handler 8-10

tonnes

Publ. no VDCF05.01GB
Workshop Manual in original WORKSHOP MANUAL

DCF 80-100
 A Foreword

B Safety

C Preventive maintenance

0 Complete machine

1 Engine
Workshop Manual
2 Transmission
DCF 80-100
3 Driveline/axle

4 Brakes

5 Steering

6 Suspension

7 Load handling

8 Control system

9 Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

D Error codes

E Schematics

F Technical data

G Terminology and index

 A:1

A Foreword

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

Workshop Manual DCF 80-100 VDCF05.01GB

A:2

VDCF05.01GB Workshop Manual DCF 80-100

 A Foreword – Foreword A:3

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

Conditions
The instructions are based on the use of generally available standard
tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet the national standards and regulations in force for lifting devices.

Cargotec will not accept any responsibility in the event of a modification

performed without permission from Cargotec. Further, Cargotec will not
accept any responsibility if other lifting devices, tools or work methods
are used other than those described in this manual.

Storage

NOTE
The workshop manual should be accessible to service personnel.

About machine version

The information in this publication corresponds with the machine's
design and appearance on delivery from Cargotec. Deviations may
arise due to customer adaptations.

Cargotec reserves the right to make changes to specifications and

equipment without prior notice. All information and data in this manual
are valid at the time of publication.

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

Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.

All duplication by any means, such as copying, printing, etc., is

prohibited.

Workshop Manual DCF 80-100 VDCF05.01GB

A:4 A Foreword – Reading instructions

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

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

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

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

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

NOTE
Important information not related to safety.

Read operator's manual

The symbol to the left is used in certain cases on the machine and
refers to important information in the operator's manual.
000262

Read the operator's manual

Read the Maintenance manual

The symbol to the left is used in certain cases on the machine and
001128

refers to important information in the Maintenance manual.

Read the Maintenance manual

VDCF05.01GB Workshop Manual DCF 80-100

 A Foreword – Reading instructions A:5

The workshop manual's contents

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

The workshop manual is divided into the following sections.

A Foreword General information about the workshop manual's purpose, contents and reading
instructions as well as survey for feedback of views and any inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance Reference to maintenance manual: Preventive maintenance.
0 Complete machine
1 Engine
2 Transmission
3 Power transmission
Technical description, comprehensive function descriptions and a description of the
4 Brakes function of components included in the machine, divided into function groups.
5 Steering The components used for each respective function are described under each
subfunction. Consequently, common components are described in several
6 Suspension locations, but in general under the first function to use the component.
7 Load handling Together with the general description is a detailed description of what is unique
about the specific subfunction. The next subfunction to use the same component
8 Control system only has a description what is unique for the new function.
9 Frame, body, cab and Work instructions for corrective maintenance (replacement of components).
accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code information.
E Schematics Wiring diagrams, hydraulic diagrams and list of electrical components.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanation of terms and abbreviations that
can appear in the sections, index for headings in the manual.

Workshop Manual DCF 80-100 VDCF05.01GB

A:6 A Foreword – Reading instructions

Function group structure

The information in the manual is divided in a structure of functions
at different levels, based on the machine's design and use, called
function groups.

The upper level (called main group) determines area, e.g. group 7
Load handling. The second level (called two-digit) determines function,
e.g. 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).

The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g. 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
made at the third and fourth group level, e.g. 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that certain function groups (headings)
will be left out in the documentation for certain machines since the
machine is missing that specific function or component. In turn, this
means that there may be jumps in the function groups' numbering, e.g.
the three-digit heading level 4.8.7 Oil cooler may be included for some
machines, but is missing for others.

The function groups are intended to be used as search terms in

order to find different types of information between different sections
and manuals. The information in a function group is divided in
smaller sections according to the type of content, e.g. description or
replacement.

The maintenance manual and workshop manual contain different

information. The maintenance manual only contains the information
needed for preventive maintenance and simpler troubleshooting.
The workshop manual contains more in-depth information and repair
instructions.

References between sections in the same manual are indicated with

section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake". References within a section are indicated with a page
number, e.g. "see Sensor fuel level, description page 24".

References between Maintenance manual and Workshop manual are

not given. If more information about a function group is required then
the primary recommendation is to search under the same function
group in the other manual. For more in-depth information on where
different types of information are located and what references are
made, see References between different information types, page A:7.

VDCF05.01GB Workshop Manual DCF 80-100

 A Foreword – Reading instructions A:7

References between different information types

The maintenance manual and workshop manual are mainly divided
into function groups, see The workshop manual's contents, page A:5.
Certain parts are broken out as separate parts to increase usability,
e.g. "Technical data".

The basic rule of searching for information is to use the function

groups to find different types of information regarding the function or
component in question. As a complement to this, there are references
in accordance with the below.

Function descriptions Hydraulic diagrams

(Technical description) (Section E)

Component descriptions
Error codes
(Technical description, normally in
(Section D)
Workshop manual)

Diagnostics Wiring diagrams

(Technical description, group 8.4) (Section E)

• From Function description to Component description, to enable

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

Workshop Manual DCF 80-100 VDCF05.01GB

A:8 A Foreword – Reading instructions

Product alternatives and optional equipment

The information in the manual is divided into modules. If a product
alternative or optional equipment is fitted, handling may differ from
that indicated in the modules depending on what is being described.
See below.

Special equipment is not described in the manual. If uncertain as

to what equipment is fitted to the machine, use the machine card to
determine which information is relevant. See Machine card, page A:9.
Product alternative
Product alternative describes options that are fitted instead of a specific
piece of standard equipment (e.g. engine alternative).

Equivalent information for different product alternatives is described

consecutively in separate segments within the same function group.
To indicate that there are different alternatives, "Product alternative"
is added to the heading together with a simple description of the
alternative, e.g. "(Product alternative Climate control system ECC)". In
addition, the alternative that is an option is marked with the symbol for
optional equipment.
Optional equipment
Optional equipment
000264

Optional equipment refers to options that can be added to standard

Symbol for optional equipment equipment for more or improved functions.

Information on auxiliary equipment is described in separate segments

together with the standard equipment as the basis. The optional
equipment description covers how the equipment option affects the
standard function and what additional components are involved.

VDCF05.01GB Workshop Manual DCF 80-100

A Foreword – Reading instructions A:9

Machine card

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

IMPORTANT
Modifications made to the machine must be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent when the customer
requests this.

The machine card indicates of which drawings the machine consists.

In many cases these can be associated with options and product
alternatives. For more information about handling of product
alternatives and optional equipment, see Product alternatives and
optional equipment, page A:8. The machine card is supplied with the
spare parts catalogue.

The machine card is divided in the same function groups as the spare
parts catalogue, maintenance and workshop manuals. For practical
reasons, the machine card only uses the first and second level in the
function group register. The function groups are written in groups of
four characters, e.g. group 0107 corresponds to group 1.7 Cooling
system in the manual.

For more information about how the machine card is used for ordering
spare parts, see the spare parts catalogue's foreword.

If the information on the machine card is not of any assistance, contact

Cargotec.

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

Workshop Manual DCF 80-100 VDCF05.01GB

A:10 A Foreword – Reading instructions

Function descriptions
The function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.

The function descriptions describe the function in a logical flow from

input signal to desired output signal. Most functions require that preset
conditions are fulfilled for the function to be activated. In these cases,
the conditions are listed above the illustration.

The function descriptions use symbols to illustrate components such

as valves, sensors, etc.

7
2

6 3

5
014725

Example of function description

1. Hydraulic force (solid double line) 4. Illustration of function, (applied brake)
2. Flag pressure check connection (Check point), 5. List of components
indicates that there is pressure check connection for
6. Position numbers in the figure, refer to the list of
checking the pressure signal
components
3. Flag diagnostic test, indicates that the signal can
7. Electric power (solid single line)
be checked with diagnostics, see section 8 Control
system, group 8.4 Diagnostics

VDCF05.01GB Workshop Manual DCF 80-100

 A Foreword – Reading instructions A:11

Symbol explanation function descriptions

Symbol explanation function descriptions
1 2
The following symbols are used in function descriptions. The symbols
3 4 are based on standard symbols for wiring and hydraulic diagrams.
1. Electric control signal
2. Electric force
5 6
3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic motor
7 8 M 6. Hydraulic oil pump with variable displacement
7. Hydraulic oil pump with fixed displacement
8. Electric motor

9 10 9. Accumulator
10. Disc brake
11. Filter
11 12 12. Radiator
13. Bulb
D790-1 14. Control and monitoring system, two control units with CAN bus
13 14 15. Restriction
D797-F 16. Adjustable restriction
17. Inductive position sensor
15 16 18. Electrically controlled servo valve
19. Thermal bypass valve
17 18 20. Temperature-controlled switch
21. Temperature sensor
19 °C 20 °C
22. Pressure sensor

°C Pa
23. Pressure-controlled switch
21 22
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
23 Pa 24
26. Spring brake cylinder
27. Valve block
25 28. Shuttle valve
29. Non-return valve

26 27

28 29
014726

Workshop Manual DCF 80-100 VDCF05.01GB

A:12 A Foreword – About the documentation

About the documentation

The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied for the machine as a separate documentation kit.
Supplementary documentation
There is supplementary documentation that can be ordered for the
machine.
• Workshop manual.
• Supplier documentation for engine, transmission, and drive axle.

Ordering documentation
Documentation is ordered from your Cargotec dealer.

Always indicate publication number when ordering.

For publication number, see machine card.

VDCF05.01GB Workshop Manual DCF 80-100

 A Foreword – Feedback A:13

Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.

Your feedback is important to be able to improve the information.

Copy this form, write down your views and send it to us. Thanks for
your help!

To: Cargotec Sweden AB

Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................

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

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

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

Manual in-
formation
Name / Publication number: .............................................................................................................................

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

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

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

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

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

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

Workshop Manual DCF 80-100 VDCF05.01GB

A:14

VDCF05.01GB Workshop Manual DCF 80-100

 B:1

B Safety

Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic system, depressurising............................................................... B:5
Oils ............................................................................................................. B:6
Fuel system ................................................................................................ B:7
AdBlue........................................................................................................ B:8
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:9
Working under the machine ....................................................................... B:9
Lifting heavy components .......................................................................... B:9
Vibration ................................................................................................... B:10
Noise ........................................................................................................ B:10
Dissolvent..................................................................................................B:11
Fire and explosion risk ............................................................................. B:12
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electric motors ......................................................................................... B:16
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:18
Spare parts............................................................................................... B:19
Non-ionised radiation ............................................................................... B:20
Environment.................................................................................................. B:21
General .................................................................................................... B:21

Workshop Manual DCF 80-100 VDCF05.01GB

B:2

VDCF05.01GB Workshop Manual DCF 80-100

 B Safety – Safety B:3

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

Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools intended for the work in
question
• wear the correct clothing
• use common sense and work carefully. Do not take any risks!

In this publication Cargotec has documented and warned for situations

and risks that may occur in connection with the use of, as well as
service or repair of, the machine during normal circumstances.

For this reason it is important that all who work with the machine, or
repair or service the machine, read and follow the information in the
Maintenance Manual and Operator's Manual.

A near accident is a warning!

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

Workshop Manual DCF 80-100 VDCF05.01GB

B:4 B Safety – Safety instructions

Safety instructions
General
Read and observe the following safety instructions below before
starting to work with the machine:
• Service position, page B:4
• Hydraulic system, depressurising, page B:5
• Oils, page B:6
• Fuel system, page B:7
• AdBlue, page B:8
• Clothing, etc., page B:8
• Several mechanics on the same machine, page B:9
• Working under the machine, page B:9
• Lifting heavy components, page B:9
• Vibration, page B:10
• Noise, page B:10
• Dissolvent, page B:11
• Fire and explosion risk, page B:12
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electric motors, page B:16
• Rotating components and tools, page B:17
• Tyres and rims, page B:17
• Lifting equipment, page B:18
• Spare parts, page B:19
• Non-ionised radiation, page B:20

Service position
General
General

Service position is used for service, maintenance and other situations

when the machine needs to be secured.

Service position entails:

• The machine is parked, i.e. parking brake applied.
• Trolley and attachment in totally lowered position
• Engine off.
• System voltage switched off (with the battery disconnector).
009797

Machine with trolley and attachment in totally lowered

position

VDCF05.01GB Workshop Manual DCF 80-100

 B Safety – Safety instructions B:5

Hydraulic system, depressurising

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

2 Depressurise the hydraulic system.

Turn system voltage on, turn the starter key to position I and
activate the load handling functions several times.
3 Turn the start key to position 0 and switch off the system voltage.

009798

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

accumulator charging valve.

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

NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
005648

5 Depressurise the attachment.

Open relief valve top lift.

CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for the attachment is closed
before starting the engine.
009961

The figure above shows open valve.

Workshop Manual DCF 80-100 VDCF05.01GB

B:6 B Safety – Safety instructions

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

WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems
before starting to work on the systems. The hydraulic
and brake systems are pressurised and the oil may
cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil may also be corrosive to mucous membranes
in, e.g. the eyes, skin and throat.

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

VDCF05.01GB Workshop Manual DCF 80-100

B Safety – Safety instructions B:7

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

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

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

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

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

Workshop Manual DCF 80-100 VDCF05.01GB

B:8 B Safety – Safety instructions

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

CAUTION
AdBlue can cause irritation in the event of contact with
the skin and eyes and inhalation.
Health hazard!
Handle with care and avoid skin contact, wear protective
gloves. In the event of skin contact and spillage on
clothing, rinse the skin with large amounts of water and
change contaminated clothing and gloves. In the event
of contact with the eyes, rinse thoroughly with water for
several minutes and seek medical advice if necessary.
If inhaled, breathe fresh air and seek medical advice
if necessary.

CAUTION
AdBlue spilled on hot components evaporates quickly.
Irritation of the eyes and respiratory system.
Turn your head away. Evaporated AdBlue may have a
corrosive effect on the mucous membranes in e.g. the
eyes and throat. In the event of contact with the eyes,
rinse thoroughly with water for several minutes and
seek medical advice if necessary. If inhaled, breathe
fresh air and seek medical advice if necessary.

IMPORTANT
Do not spill AdBlue on the ground and in water.
Spillage on the ground must be absorbed with sand or
other absorbent non-combustible material.

Clothing, etc.
Clothes should be in good repair. Remove loosely hanging garments
(e.g. tie, scarf). Do not wear clothes with wide sleeves, wide trouser
legs, etc.

Remove jewellery as it may conduct electricity and get caught in

moving parts.

Long hair should be adequately gathered since it can easily get caught
in moving parts. Exercise caution when working with welding or an
naked flame since hair easily catches on fire.

VDCF05.01GB Workshop Manual DCF 80-100

B Safety – Safety instructions B:9

Several mechanics on the same machine

WARNING
If several mechanics are working on the same vehicle,
extra care must be taken so that accidental movements
do not injure any other person. Communicate so that
everyone knows where everyone is, and what they are
doing.

Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.

Operations controlled from the operator's station, e.g. all movement of

lifting equipment, may cause severe personal injury.
Safety precautions
• Make sure that the machine's lifting equipment is completely
lowered or secured in some other way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons are working around
the vehicle.
• Make your co-workers aware of what you are working with.
• Do not work with the drive wheels on the both sides of the machine
at the same time.

Working under the machine

Working under the frame

A raised vehicle may not, for any reason, be supported or raised in

parts that belong to the wheel suspension or steering. Always support
under the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices may fall over or
accidentally lower due to malfunctions or incorrect use.
Safety precautions
• Use axle stands and supports that stand securely.
• Lifting tools should be inspected and type approved for use.

Lifting heavy components

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

Workshop Manual DCF 80-100 VDCF05.01GB

B:10 B Safety – Safety instructions

Risks

Unsuitable lifting straps, etc. may break or slide.

The centre of gravity of the component may shift while work is in

progress, and the component may then make unexpected movements
which may cause severe personal injury and material damage.

A component lifted with lifting equipment may start to turn if the centre
of gravity shifts.

A component lifted using an overhead crane may start to swing

back and forth, which can cause severe crushing injuries or material
damage.

Safety precautions

Lifting with lifting device. Use lifting tools or other tools, in particular
when there are such tools available adapted for specific work
operations. See the workshop manual for methods.

If lifting must be performed without lifting device:

• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
• Wear gloves. They're often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.

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

Safety precautions
• Use heavy gloves that protect against the cold and the transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary your work position and grip so that your body is not affected
in only one position by the vibration.

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

Risks

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

Safety precautions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing screens, for example,
noise-absorbing materials in roof and on walls.

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B Safety – Safety instructions B:11

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

Risks

Products with dissolvents give off fumes that may cause dizziness,
headache and nausea. They may also irritate mucous membranes
in the throat and bronchi.

If dissolvent comes in direct contact with the skin it can dry and crack.
Increased risk of skin allergies. Dissolvents may also cause injury if
they penetrate through the skin and are absorbed by the blood.

If the body is continuously exposed to dissolvents, there may be

damage to the central nervous system. This manifests itself in
sleeping problems, depression, nervousness, poor memory and
general tiredness. Continuous inhalation of petrol and diesel fumes is
suspected to cause cancer.

Safety precautions
• Avoid inhaling dissolvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a dissolvent container without tight-sealing lid.
• Use dissolvents with a low content of aromatic substances. This
reduces the risk of injury.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are dissolvent-resistant.

Workshop Manual DCF 80-100 VDCF05.01GB

B:12 B Safety – Safety instructions

Fire and explosion risk

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

DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people! Smoke
can cause damage to lungs and respiratory organs
even in small quantities.
Avoid breathing fumes, do not stand in the smoke.
Use breathing apparatus for fire fighting and work with
burnt material.

Examples of fire and explosion prone substances are oils, petrol, diesel
fuel oil, organic solvents (paint, plastics, detergents), rust preventive
agents, welding gas, gas for heating (acetylene), high concentrations
of dust particles consisting of combustible materials. Rubber tyres are
flammable and can cause fire with explosive development.

Risks

Examples of the cause of ignition are welding, cutting with gas flame,
tobacco smoking, sparks when grinding with grinding machines,
contact between hot engine parts and flammable materials, heat
generation in rags soaked with oil or paint (linseed oil) and oxygen.
Oxygen containers, lines and valves must be kept clean of oil and
grease.

Fumes from e.g. fuel are heavier than air and may "run" down a slope,
or down into a grease pit, where welding flames, grinding sparks or
cigarette embers may cause an explosion. Vaporised fuel has a very
powerful explosive effect.

VDCF05.01GB Workshop Manual DCF 80-100

B Safety – Safety instructions B:13

Special cases

Diesel fuel oil with added petrol has a lower flashpoint. Risk of
explosion even at room temperature. The explosion risk for heated
diesel fuel oil is higher than for petrol.

When changing the oil in the engine, hydraulic system and

transmission, keep in mind that the oil may be hot and cause burn
injuries.

Welding on or in the vicinity of the machine. If diesel or other oils

have leaked and soaked rags, Absol/absorbing agents, paper or other
porous material then glowing welding sparks can cause ignition and
the explosive spread of fire.

When a battery is being recharged the battery electrolyte water is

divided into oxygen and hydrogen gas. This mixture is highly explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge unit is used, as they increase the risk of sparks.

There is a lot of electronic equipment on today's machines. When

welding, the control units must be disconnected and the electric power
must be switched off with the battery disconnector. Powerful welding
currents may otherwise short-circuit the electronics, destroy expensive
equipment or cause an explosion or fire.

Never weld on painted surfaces (remove paint, by blasting at least

10 cm around the welding or cutting point). Use gloves, breathing
protection and protective glasses. Also, welding work must not be
done near plastic or rubber materials without first protecting them from
the heat. Paints, plastics and rubber develop a number of substances
when heated that may be hazardous to health. Exercise caution with
machines that have been exposed to intense heat or fire.

Safety precautions

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

• Make it a habit to make a visual inspection of the engine and

engine compartment before starting the engine and after operation,
when the engine has been stopped. This helps to quickly detect
if anything abnormal has happened or is about to happen. Look
particularly closely for oil, fuel or coolant leakage, loose bolts, worn
or poorly tensioned drive belts, loose connections, damaged hoses
and electrical cables. The inspection only takes a few minutes and
can prevent serious faults and costly repairs.
• Store a hazardous substance in an approved and sealed container.
• Make sure that there is no ignition source near flammable or
explosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.

Workshop Manual DCF 80-100 VDCF05.01GB

B:14 B Safety – Safety instructions

Fluid or gas under pressure

Lines with high pressure may be damaged during work and fluid or
gas may jet out.

There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid may leak out when the connection for the hose
is loosened.

A gas container that is subjected to external forces may explode, e.g. if

it falls against a hard surface. Gas may jet out from damaged valves.

Risks

Risk of damage/injury in connection with work on:

• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changing.
• Air conditioning.
• Cooling system.

Safety precautions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g. at a connection, shows evidence
that it is about to rupture. Replace it as soon as possible! Check
the connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• A discarded pressure accumulator must first be depressurised and
then punctured before it is discarded (to avoid risk of explosion).
Carefully, drill a hole with 3 mm diameter after depressurising.
• Never use your hands to check for any leaks. A fine jet from a
hydraulic hose may have such high pressure that it easily cuts
through e.g. a hand and causes very severe injuries.
• First open the cooling system cap for the filling point slowly, so
that the high pressure is released. Hot steam and coolant may
otherwise spray out.

Coolant
The coolant in the machine's cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.

Coolant must not be drained into the sewer system or directly onto
the ground.

Risks

The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in the event of leaks or when
the cap on the expansion tank (filling point) is opened.

Ingesting ethylene glycol and anti-corrosion compound is dangerous

and hazardous to health.

VDCF05.01GB Workshop Manual DCF 80-100

B Safety – Safety instructions B:15

Safety precautions
• Use protective gloves and protective safety glasses if there is a
risk of splashing or spraying.
• First open the cap for the filling point slowly, so that the high
pressure is released. Exercise caution. Hot steam and coolant
may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.

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

Work on the air conditioning system must be performed by

accredited/authorised and trained personnel in accordance with
national legislation and local regulations.

Risks

The air conditioning operates at high pressure. Escaping refrigerant

can cause frostbite.

Refrigerant that is heated (e.g. when repairing leaking climate/AC

system), generates gases that are very dangerous to inhale.

Safety precautions
• Use special instructions and equipment for refrigerant according to
the manual when working on the air conditioning system. Special
certification and authorisation must often be held by the person
who may do the work. (Observe national legislation and local
regulations!)
• Use protective gloves and protective safety glasses if there is
a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).

Air pollution
Air pollutants are the impurities in the air around us and are regarded
as hazardous to health. Certain impurities are more prevalent in
certain environments.

The following health-hazardous air pollution is particularly prominent in

workshops:
• Carbon monoxide (fumes) is contained in exhaust gases.
Odourless and therefore particularly dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke is particularly hazardous to health when welding
on oily surfaces, galvanised or lacquered materials.
• Oil mist for example, is formed when applying anti-corrosion
agent.
• Grinding dust and gases are generated when grinding and
heating plastics, lacquer, anti-corrosion agents, lubricants, paint,
etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.

Workshop Manual DCF 80-100 VDCF05.01GB

B:16 B Safety – Safety instructions

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

Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
formed.
• Use suitable protective gloves and breathing protection when there
is a risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine in the workshop.
Connect extraction equipment to the exhaust pipe so that exhausts
are routed out from the workshop.

Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g. pedals
2. Thrust spring (cup springs) in parking brake cylinder
3. Lock rings
4. Gas springs

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

Safety precautions
• Use protective safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when performing
maintenance and replacing parts and components.
• Always use the tools recommended.

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

VDCF05.01GB Workshop Manual DCF 80-100

B Safety – Safety instructions B:17

Rotating components and tools

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines

Risks

Rotating components, e.g. fans or shafts, can cause severe injury

if touched.

Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothing or hair gets caught and becomes wound
into the machine.

Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.

Tyres and rims

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

Risks

Dismantling of wheels: Tyres, rims and lock rings may be ejected.

Inflating of tyres: Tyres, rims or lock rings may be ejected.

Safety precautions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings are not damaged. Never
repair damaged wheel rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and protective safety glasses.

Workshop Manual DCF 80-100 VDCF05.01GB

B:18 B Safety – Safety instructions

Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest caution must be exercised with
respect to securing the mast, carriage and attachment.

Always make a habit of lowering the carriage to its lowest position

before working on the machine.

Risks

If the machine's lifting equipment is not lowered or secured, there is a

risk of crushing.

Risk of crushing is particularly great when depressurising the hydraulic

system, see Hydraulic system, depressurising, page B:5.

Safety precautions

Do not begin work until the carriage has been fully lowered. If the
nature of the work requires the carriage to be raised then this must
be secured in some way.

VDCF05.01GB Workshop Manual DCF 80-100

B Safety – Safety instructions B:19

Spare parts

WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Lift cylinder
• Valve block lift
• Tilt cylinder
• Twistlocks, lifting hook
• Control breaker (for hydraulic function)
• Emergency stop
• Hydraulic cylinders, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units

Workshop Manual DCF 80-100 VDCF05.01GB

B:20 B Safety – Safety instructions

Non-ionised radiation

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

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

VDCF05.01GB Workshop Manual DCF 80-100

 B Safety – Environment B:21

Environment
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.

There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.

By following the simple rules below, you will contribute to protecting

our environment.

Recycling

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

Environmentally hazardous waste

Components such as batteries, oils, and various chemicals and other

items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.

Discarded batteries contain substances hazardous to personal health

and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.

Oils and fluids

Oils freely discharged cause environmental damage and can also be a

fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.

Waste oils and fluids should always be taken care of by an authorised

disposal company.

Pay close attention to oil leaks and other fluid leaks! Rectify leakage
immediately.

Air conditioning

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

Working in a contaminated area

The machine must be equipped for work in contaminated areas

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

Workshop Manual DCF 80-100 VDCF05.01GB

B:22 B Safety – Environment

Declarations

The machine does not contain asbestos.

The machines contains lead in batteries and in electric cabling. In

certain models, there are lead castings as counterweight.

If the machine is equipped with air conditioning, refrigerant of type

R134a is used, in an amount totalling between 1-3 kg.

VDCF05.01GB Workshop Manual DCF 80-100

 C:1

C Preventive maintenance

C Preventive maintenance
The information is available in the
Maintenance Manual
The information is available in the Maintenance Manual.

For information on how to order the Maintenance Manual, see the

section A Foreword.

Workshop Manual DCF 80-100 VDCF05.01GB

C:2

VDCF05.01GB Workshop Manual DCF 80-100

 0:1

0 Complete machine

Contents 0 Complete machine

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

Workshop Manual DCF 80-100 VDCF05.01GB

0:2

VDCF05.01GB Workshop Manual DCF 80-100

 0 Complete machine – Complete machine 0:3

0 Complete machine
Complete machine, description
Kalmar DCF80-100 is a machine with a mast to handle empty
containers. The machine has a lift capacity of up to 8-10 tonnes
depending on the version.

The engine is a straight six-cylinder, four-stroke, turbocharged

low-emission diesel engine with a unit injector, air to air intercooling
and electronically controlled fuel injection.

The transmission is hydromechanical with gear wheels constantly

engaged and has three gears in each direction. Engine power is
transmitted using a torque converter.

The power transmission consists of a propeller shaft and one rigid

1 2 3 4 5 6 7 8 9 drive axle with differential and hub reduction. Drive takes place on
the front wheels.

The service brakes are wet multiple disc brakes which are attached
to the drive wheel hub. The parking brake is the disc brake type and
operates on the drive axle input shaft.

Steering operates on the rear wheels with a double acting hydraulic

cylinder. The steering axle is suspended in the frame with pendulum
suspension.

The wheels are mounted on the hubs with nuts and clips. Double
wheels are fitted on the drive axle; single wheels on the steering axle.

Load handling comprises components and functions for handling

loads. The load is lifted with the side lift attachment secured to a
009775

trolley that sits on a mast. Load handling is divided into the functions:
lift and lower, tilt, side shift, spreading, levelling and load securing.
1. Counterweight Lifting/lowering is the function used to raise and lower the trolley. Side
shifting is moving the side lift attachment sideways along the trolley.
2. Steering axle Spreading is adjusting the width between the Twistlocks alternative
3. Cab Lifting hooks on the side lift attachment. Tilt is used to angle the load
4. Hydraulic oil tank in the longitudinal direction of the truck with the help of the mast.
Levelling is to angle the side lift attachment in the lateral direction of
5. Drive axle the truck. Load securing is to lock the load to the side lift attachment.
6. Tilt cylinder
The control system consists of functions for warning the operator of
7. Trolley dangerous situations and faults. The control system has diagnostic
8. Mast resources that simplify troubleshooting.
9. Side lift attachment
The frame carries the machine. The frame houses the engine,
transmission, drive axle and steering axle. Fuel and hydraulic oil
tanks are fitted to the side of the frame. The cab is located at the rear
of the frame. As an option, the cab can be tilted.

Workshop Manual DCF 80-100 VDCF05.01GB

0:4 0 Complete machine – Complete machine

The hydraulic system is fed by four hydraulic oil pumps, the pumps are
assembled into two pump banks that are mounted on the transmission's
power take-off. Three variable pumps feed load handling, steering and
other hydraulic functions. A fixed pump feeds the brake system's brake
and cooling circuit over an accumulator charging valve. The hydraulic
oil tank is located on the right side of the machine. The hydraulic oil
filters are return filters fitted in the hydraulic oil tank.

The machine's electrical system is built around control units at strategic

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

VDCF05.01GB Workshop Manual DCF 80-100

0 Complete machine – Complete machine 0:5

Troubleshooting, general work

instructions
When troubleshooting, it is important that the work is structured
and logical. The purpose of the troubleshooting described in the
maintenance manual is to exclude components as the source of a
fault so that the real source can be identified. A suggested structured
work method is described below.

When troubleshooting, it is important to understand how the machine

functions. Certain faults can be identified directly using function
descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available.
• Battery disconnector, must be in position 1.
• Battery voltage, should be 22–30 V.
• Fuses, check that they are intact.

2 Check that all oil and fluid levels are normal.

• Fuel
• AdBlue
• Engine oil
• Transmission oil
• Hydraulic oil
• Coolant
• Washer fluid

3 Check if there are error codes.

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

5 If there is no error code or the problem persists, use the function

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

Troubleshooting without an error code,

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

2 Read the function description for the function in question to get

an overall understanding of which components are affected and
how these interact.

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

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

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0:6 0 Complete machine – Complete machine

5 If the component that is to send the signal seems to be intact,

check the transmission of the signal (electric cables or hydraulic
hoses).
For electric cables, see Troubleshooting cable harnesses, page
0:7.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:8.

6 If the cables or hoses between the components seem to be intact,

then check the component that receives the signal.

Troubleshooting with an error code,

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

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

3 Follow the instructions in the field "Action".

4 Use diagnostic menus and circuit diagrams to determine if the

input signal to the control unit is correct; see section 8 Control
system, group 8.4 Diagnostics as well as section E Schematics.

5 Use the function group to find more information if needed.

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

6 If possible, eliminate component faults by testing the component

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

7 If the component's measurement values are correct, continue by

troubleshooting electric cables and hydraulic hoses.
For electric cables, see Troubleshooting cable harnesses, page
0:7.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:8.

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

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

9 Disconnect the cable harness from the component in question.

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 0 Complete machine – Complete machine 0:7

10 Switch on the system voltage with the battery disconnector.

11 Turn the ignition key to operating position.

12 Check that voltage reaches the component.

Table Example of error code information in error code list

Connec-
Cod- tions and Diagnostic Function
Description Limitation Action
e compo- menu group
nents
34 Signal error from Parking brake Check cabling D791-1/K8:5 - HYD, menu 4.1.2 Parking
parking brake cannot be between the S107, K8:13 - 5 brake control
switch, indicates released. control unit and the S107
released and component with
applied at same diagnostic menu.
time or nothing at
Check component.
all.

Troubleshooting cable harnesses

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

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

cable is connected and if, and if so where, it is spliced.

2 Turn off the system voltage with the battery disconnector.

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

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

4 Check if there is an open circuit.

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

a. Measure resistance between connections to the component in

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

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0:8 0 Complete machine – Complete machine

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

a. Unplug the connector at both the control unit and the
component in question.
b. Measure the resistance in one cable at a time. Measure
between the cable and a frame-connected part of the machine.
c. The multimeter should show infinite resistance.

Troubleshooting hydraulic hoses

WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems
before starting to work on the systems. The hydraulic
and brake systems are pressurised and the oil may
cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil may also be corrosive to mucous membranes
in, e.g. the eyes, skin and throat.

1 Depressurise the hydraulic and brake systems, see section B

Safety.

2 Study the hydraulic diagram in question, check between which

components the suspect hose is connected and if, and if so where,
it is spliced.

3 Locate the hose on the machine.

Start at one component and follow the hose to the next component.

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

VDCF05.01GB Workshop Manual DCF 80-100

 1:1

1 Engine

Contents 1 Engine
1 Engine..................................................................................................................1:3
1.1 Controls and instruments ...............................................................................1:15
1.1.1 Ignition.......................................................................................................1:15
1.1.2 Accelerator ................................................................................................1:16
1.2 Fuel system....................................................................................................1:17
1.2.1 Fuel tank ...................................................................................................1:17
1.2.2 Sensor fuel level........................................................................................1:18
1.6 Air intake and exhaust outlet..........................................................................1:19
1.6.1 Air cleaning system ...................................................................................1:19
1.6.3 Exhaust system .........................................................................................1:20
1.6.4 Intercooler .................................................................................................1:21
1.6.8 SCR system ..............................................................................................1:22
1.7 Cooling system ..............................................................................................1:23
1.7.4 Radiator and expansion tank ....................................................................1:23
1.7.5 Cooling fan ................................................................................................1:24
1.7.7 Coolant ......................................................................................................1:24
1.7.8 NO (normally open) switch, coolant level ..................................................1:28
1.7.10 Engine heater ............................................................................................1:28
1.9 Control system, engine ..................................................................................1:29
1.9.1 Engine control unit ....................................................................................1:29
1.11 Start/stop........................................................................................................1:30
1.11.1 Starter motor .............................................................................................1:30
1.11.2 Stopping device.........................................................................................1:30

Workshop Manual DCF 80-100 VDCF05.01GB

1:2

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 1 Engine – Engine 1:3

1 Engine
Engine, general
The machine is equipped with the Volvo TAD762VE.
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the engine's components and systems, refer to the
relevant supplier documentation.

References to supplier documentation are only provided in exceptional

cases. If information about a component is not found, the component
supplier documentation should be used.

Workshop Manual DCF 80-100 VDCF05.01GB

1:4 1 Engine – Engine

Engine, function description

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

Condition Reference value Reference

Disconnected (when cable is in start lock-out is activated). Engine heater, description, page 1:28
Engine heater

°C

. bar

0 rpm
P I kph

II

III D5
1, 5
10 <°

D10 D1

6, 15
2, 11 18, 21
D794 UDS D790-1 D790-2 D795
3, 7, 12, 14, 23, 32 25, 28,
20, 22 29, 31
D793 D797-1
D14 17

D19 D3
D16
D7

H2O
SENSORS M M
19 4 13 24 27 16
9 8 30
26

014764
Pos Explanation Signal description Reference
1 The ignition switch (S150) sends U = 24 V Ignition key lock, description, page 1:15
a voltage signal to cab control unit
D1: Diagnostic menu, see section 8 Control
KCU (D790-1) when the start key is
system, group 8.4.1.4 CAN/POWER, menu 4
turned to position 1 or the preheating
and 8.4.6.4 ENGINE, menu 4
position.
2 Cab control unit KIT (D790-2) sends Checked by control See section 11 Common electrics, group
ignition on via the CAN bus. If system, error shown with 11.5.3.11 Control unit KIT (D790-2)
the key is turned to the preheating error code.
position, then preheating is also sent
on the CAN bus.
3 If preheating has been activated with U = 24 V See Control unit, engine, general, page 1:29
the start key or automatically, then
D3: Diagnostic menu, see section 8 Control
the engine control unit (D794) feeds
system, group 8.4.6.5 ENGINE menu 5
voltage to the preheating relay and
through this also the preheating coils
(E800-1).
4 The preheating coils (E800-1) warm - D4: Diagnostic menu, see section 8 Control
each cylinder with a glow plug. system, group 8.4.6.5 ENGINE menu 5
5 The ignition switch (S150) sends a U = 24 V Ignition key lock, description, page 1:15
voltage signal to the KIT control unit
D5: Diagnostic menu, see section 8 Control
(D790-2) when the start key is turned
system, group 8.4.6.4 ENGINE menu 4
to start position.

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 1 Engine – Engine 1:5

Pos Explanation Signal description Reference

6 Control unit KIT (D790-2) sends a - See section 11 Common electrics, group
start signal on the CAN bus. 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is U = 24 V Starter motor, description, page 1:30
controlled by the engine control unit
D7: Diagnostic menu, see section 8 Control
(D794) through starter relays and
system, group 8.4.6.5 ENGINE menu 5
receives signals from the cab control
unit (D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description, page 1:30
engine.
9 The engine's sensor sends signals - See section 11 Common electrics, group
to Control unit, engine (D794) that 11.5.3.10 Engine control unit
controls the injectors so the engine
starts.
10 The accelerator pedal (B690) sends U = 0.5-4.5 V Section 9 Frame, body, cab and accessories,
the cab control unit (D790-1) a group 9.1 Controls and instruments
Lower voltage than 0.5 V
voltage signal proportional to the
and higher voltage than D10: Diagnostic menu, see section 8 Control
downward press of the pedal.
4.5 V is used to detect system, group 8.4.6.1 ENGINE menu 1
faults in cable harnesses
and controls.
11 Control unit, cab (D790-1) sends a Checked by control See section 11 Common electrics, group
message with the rpm request on system, error shown with 11.5.3.1 Cab control unit (D790-1)
the CAN bus. error code.
12 Control unit, engine (D794) increases - Section 11 Common electrics, group 11.5.3.10
the engine speed. Control unit, engine
13 The NO switch for coolant level U = 24 V 1.7.8 NO (normally open) switch, coolant level,
(B759) sends a voltage signal to page 1:28
the engine control unit (D794) if the
coolant level in the expansion tank
is low.
14 Control unit, engine (D794) sends Checked by control Section 11 Common electrics, group 11.5.3.10
engine data and warning messages system, error shown with Control unit, engine
on the CAN bus. error code.
D14: Diagnostic menu, see section 8 Control
system, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7
ENGINE, menu 7 and 8.4.6.8 ENGINE, menu 8
15 Control unit KID (D795) shows - See section 11 Common electrics, group
engine data via display figures. 11.5.3.12 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0-70 ohm Sensor, fuel level, description, page 1:18
the frame control unit (D797-1) a
D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel
system, group 8.4.3.7 CAB, menu 7
level in the tank.
17 The frame control unit (D797-1) Checked by control See section 11 Common electrics, group
transmits fuel level on the CAN bus. system, error shown with 11.5.3.2 Frame control unit (D797-1)
error code.
18 The KID control unit (D795) shows - See section 11 Common electrics, group
fuel level in the operating menu for 11.5.3.12 KID control unit (D795)
engine and transmission.
19 Speed limitation - D19: Diagnostic menu, see section 8 Control
system, group 8.4.7.6 TRANSM menu 6
The output shaft speed sensor
(B758) sends the transmission
control unit (D793) pulses with
frequency proportional to output
shaft rpm.
20 Control unit, transmission (D793) Checked by control See section 11 Common electrics, group
transmits the speed on the CAN bus. system, error shown with 11.5.3.9 KIT control unit (D793)
error code.
21 The KID control unit (D795) shows - See section 11 Common electrics, group
the machine's speed. 11.5.3.12 KID control unit (D795)

Workshop Manual DCF 80-100 VDCF05.01GB

1:6 1 Engine – Engine

Pos Explanation Signal description Reference

22 If the rotation speed of the output Checked by control See section 11 Common electrics, group
shaft is so high that it corresponds system, error shown with 11.5.3.1 Cab control unit (D790-1)
with the limit for the machine's error code.
speed limitation then Control unit,
cab (D790-1) sends reduce engine
speed on the CAN bus.
23 Control unit, engine (D794) limits the - Section 11 Common electrics, group 11.5.3.10
engine speed. Control unit, engine
24 AdBlue level and temperature sensor U = 0.5-4.5 V SCR system, description, page 1:22.
sends Control unit SCR (UDS) a
voltage signal proportional to the
AdBlue level and temperature in the
tank.
25 In the event of cold AdBlue, Control U = 24 V SCR system, description, page 1:22.
unit SCR (UDS) voltage feeds the
water valve.
26 The water valve leads warm water to - SCR system, description, page 1:22.
the AdBlue tank to heat it.
27 Exhaust gas temperature sensor U = 0.5-4.5 V SCR system, description, page 1:22.
sends Control unit SCR (UDS) a
voltage signal proportional to the
temperature of the exhaust gases.
There is a damper located after the
intercooler that helps to increase
the temperature of the exhaust gas
when necessary.
28 The NOx sensor continuously U = 0.5-4.5 V SCR system, description, page 1:22.
measures the amount of nitrogen
oxide in exhaust gases and sends
the voltage signal to the Control unit
SCR (UDS).
29 The Control unit SCR (UDS) voltage U = 24 V SCR system, description, page 1:22.
feeds the AdBlue pump.
30 The AdBlue pump pumps AdBlue -
from the AdBlue tank. The right
amount of AdBlue is injected into
the silencer inlet depending on
the amount of nitrogen oxides in
exhaust gases. AdBlue and exhaust
gases are mixed before passing the
catalytic converter (SCR), which is
located centrally in the silencer.
31 If the levels of nitrogen oxides in - SCR system, description, page 1:22.
the exhaust gases are too high, the
Control unit SCR (UDS) sends a
request to the engine Control unit
(D794) on the CAN bus to restrict the
engine speed.
32 Control unit, engine (D794) limits the - Section 11 Common electrics, group 11.5.3.10
engine speed. Control unit, engine

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 1 Engine – Engine 1:7

Engine, component position

7
6
5
4
3
8
2
9
1

10

11

12
13
14
15
16
17
18
19
20

014546
22 21
Volvo TAD762VE, left side (in machine's direction of travel)
1. Sensor flywheel speed 12. Fuel pump
2. Crankcase ventilation 13. Oil filter
3. Filling point engine oil 14. Sensor oil pressure
4. Injector and preheating (6 pcs.) 15. Fuel filter
5. Dipstick 16. Control unit, engine (D794)
6. Air preheating downstream of intercooler 17. Sensor fuel pressure
7. Sensor coolant level (B757) 18. Oil plug
8. Sensor coolant temperature 19. Fuel pre-filter
9. Thermostat housing 20. Sensor water in fuel
10. Alternator 21. Water separator
11. Water pump 22. Sensor camshaft rpm

Workshop Manual DCF 80-100 VDCF05.01GB

1:8 1 Engine – Engine

4
3
2
5
1

11

10

014547
9
8
Volvo TAD762VE, right side (in machine's direction of travel)
1. Expansion tank 7. Starter motor
2. Filling coolant 8. Intercooler
3. Connection cab heating 9. Condenser
4. Sensor charge air pressure and temperature 10. Transmission oil cooler
5. Sensor fuel pressure (distribution pipe) 11. Radiator, engine
6. Turbo

VDCF05.01GB Workshop Manual DCF 80-100

 1 Engine – Engine 1:9

0
P I
4
2 II 3 5
III

6
11

9
10 7
8

014715
Machine electrical components
1. Accelerator pedal (B690) 7. Control unit, transmission (D793)
2. Ignition key lock (S150) 8. Fuel tank
3. KIT cab control unit (D790-2) 9. Sensor fuel level (B757)
4. Control unit, KID (D795) 10. Frame control unit (D797-1)
5. Control unit, cab (D790-1) 11. Frame option control unit (D797-2)
6. Control unit, engine option (D794)

Workshop Manual DCF 80-100 VDCF05.01GB

1:10 1 Engine – Engine

Engine and transmission, separation

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

1 Machine in service position, see section B Safety.

2 Attach hoisting equipment to the engine.

3 Disconnect the requisite hoses and cables before separating

engine and transmission.

NOTE
Drain and collect liquids before detaching hoses.

4 Remove the radiator.

5 Use a jack to secure the transmission.

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

VDCF05.01GB Workshop Manual DCF 80-100

 1 Engine – Engine 1:11

7 Remove the nuts for the flex plate through the hole under the
cover washer.

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

8 Take up the slack in the hoisting equipment.

NOTE
Do not lift the engine.

9 Remove the bolts between engine and transmission.

10 Remove the screws in the engine brackets.

11 Carefully separate the transmission and engine. Withdraw the

engine rearwards to separate it from the transmission.
12 Lift the engine away.
007780

NOTE
Beware of balance before the engine is lifted.

Workshop Manual DCF 80-100 VDCF05.01GB

1:12 1 Engine – Engine

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

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

008301

14 Insert two studs into the flywheel housing as a guide when the
engine is installed.
15 Transfer the engine brackets to the new engine; tighten to 169
Nm (oiled screw).
007775

16 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772

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 1 Engine – Engine 1:13

17 Lift the engine into place. Make sure that the studs on the flywheel
come into correct alignment and do not damage the flex plate.
18 Install the bolts that affix the transmission and engine, but do
not tighten the bolts fully. Leave about a millimetre between the
engine and transmission to facilitate installation of the nuts for the
flex plate/flywheel.

007776
19 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and torque tighten the nuts to 40 Nm (oiled screw).

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

20 Tighten the screws which fix the transmission and engine. Tighten
the transmission to the transmission mountings. Refit the cover
plate and propeller shaft.

Workshop Manual DCF 80-100 VDCF05.01GB

1:14 1 Engine – Engine

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

22 Fit the screws in the engine bracket.
Tighten to 169 Nm (oiled screw).
23 Fit the cover washer under the flywheel.
24 Remove the hoisting equipment from the engine.
25 Remove the jack from under the transmission.
26 Connect the requisite hoses and cables for the engine and
transmission. Check and fill fluids as required.
27 Bleed air from the engine's fuel system before starting.

007973

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 1 Engine – Controls and instruments 1:15

1.1 Controls and instruments

1.1.1 Ignition
Ignition key lock, description
P No function.
0 Stop position. Everything switched off, the key can be
removed.
I Operating position.
Voltage to all electrical functions. Control units for the engine
and transmission are now active.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.6.4 CAN/POWER, menu
4.
II Preheating position (function applies to Volvo engines only).
The preheating mode heats the engine's intake air manually
with glow plugs in each cylinder to the appropriate temperature
on Volvo engines. The preheating lamp is lit during preheating.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.6.4 ENGINE, menu 4.
0
III Start position.
P I Engagement of starter motor for engine start.

NOTE
II The machine is equipped with an electric restart interlock,
which prevents engagement of the starter motor when the
engine is rotating.
Condition for starter motor to engage is that the transmission
000317

III is in neutral position and that the engine isn't already

running.

The signal can be checked via the diagnostic menu. See

section 8 Control system, group 8.4.6.4 ENGINE, menu 4.

Workshop Manual DCF 80-100 VDCF05.01GB

1:16 1 Engine – Accelerator

1.1.2 Accelerator
Accelerator pedal, replacement
1 Machine in service position, see section B Safety.

2 Pull one edge of the cover away to facilitate access to the

accelerator pedal.

3 Disconnect the cable harness from the connector.

4 Unscrew the connector from the accelerator pedal.
5 Replace the accelerator pedal.
6 Fit in the reverse order.
7 Calibrate the accelerator pedal. See section 8 Control system,
group 8.5.2.3 Calibrate DRIVE-TRAIN.

1. Accelerator
2. Brake pedal

Accelerator pedal, calibration

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

VDCF05.01GB Workshop Manual DCF 80-100

 1 Engine – Fuel system 1:17

1.2 Fuel system

Fuel system, description
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the
tank is shown in an operating menu on the display in the cab. Fuel
prefilter with water trap and fuel filter are on the engine. The water trap
is equipped with electrical indication, an event menu appears in the
display when the water trap must be emptied of water.

For component locations, see the section 1 Engine.

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

1.2.1 Fuel tank

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

3
1
014209

1. Fuel filling
2. Drain plug, under tank
3. Fuel tank

Workshop Manual DCF 80-100 VDCF05.01GB

1:18 1 Engine – Sensor fuel level

1.2.2 Sensor fuel level

Sensor, fuel level, description
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.3.7 CAB, menu 7.

015680

1. Sensor fuel level

VDCF05.01GB Workshop Manual DCF 80-100

 1 Engine – Air intake and exhaust outlet 1:19

1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air cleaning system, description
The air cleaning system consists of an air cleaner with filter, filter
indicator, pipes and hoses. There are two filters in the air cleaner that
purify the air and a dust reservoir that collects larger particles. The
2 dust reservoir can be emptied without opening the air cleaner.
3
Combustion in the engine requires air. Free unobstructed flow for
fresh air and exhaust gases is essential for efficient engine operation.
Particles are collected in the filter material when the air filters clean
the air to the engine. Over time, a great deal of particle matter is
1 collected and the filter does not let through sufficient air for efficient
combustion, the filter must then be changed. The filter indicator
measures the negative pressure on the engine side of the filter. When
008040 the filter is clogged the negative pressure is higher and the indicator
indicates that it is time to replace the filter.

1. Dust reservoir
As an option the machine can be equipped with a raised air intake
2. Air cleaner
with pre-cleaner. It consists of an extension of the inlet to the air filter
3. Filter indicator and a pre-cleaner that sorts out larger particles by creating vortices in
the air intake. The pre-cleaner does not contain any parts that need
to be replaced. During operation in dirty environments this means
that less dusty air is sucked into the air cleaner, and in this way the
service life of the air filters is extended.

Workshop Manual DCF 80-100 VDCF05.01GB

1:20 1 Engine – Exhaust system

1.6.3 Exhaust system

Exhaust system, description

3
2
1

8 6

7
11
10
9

014287

1. Control unit NOx 7. Sensor level and temperature AdBlue

2. Silencer with integrated SCR catalytic converter 8. Exhaust pipe
3. Catalyst 9. AdBlue tank
4. End pipe 10. Pump unit
5. Heat protection 11. Heating valve
6. Injection unit

The exhaust system is mounted in the chassis. Heat protection is fitted

between the engine and exhaust system to protect cables, etc. A flex
pipe between the turbo and silencer takes up engine movement. On
the outside of the machine, there is heat protection fitted over the
exhaust system.

VDCF05.01GB Workshop Manual DCF 80-100

 1 Engine – Intercooler 1:21

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

1.6.4 Intercooler
Intercooler, description
The charge air is cooled by an air to air intercooler.
1
See also Cooling system, description, page 1:23.

5
4
3
014763

2
Cooling unit
1. Expansion tank
2. Intercooler
3. Condenser
4. Transmission oil cooler
5. Radiator, engine

Workshop Manual DCF 80-100 VDCF05.01GB

1:22 1 Engine – SCR system

1.6.8 SCR system

SCR system, description
SCR technology (Selective Catalytic Reduction) - catalytic converters -
are used to meet statutory emission requirements.

Diesel engines with even more efficient combustion in combination

with exhaust after-treatment provide significantly reduced emissions
of nitrogen oxides and particles.

SCR technology is based on exhaust gases being after treated through

the addition of AdBlue solution which is injected into the exhaust gases
before they pass through the catalytic converter. This addition converts
nitrogen oxides into nitrogen and water vapour, natural substances
in our environment.

Diesel engines have been developed toward more efficient combustion

levels and its control unit calculates the optimum amount of AdBlue
solution to be injected in relation to the current load and engine speed.

For more information, see supplier documentation, engine.

SCR system, component placement

See Exhaust system, description, page 1:20.

VDCF05.01GB Workshop Manual DCF 80-100

 1 Engine – Cooling system 1:23

1.7 Cooling system

Cooling system, description
The engine is water-cooled and has passages through which the
coolant from the radiator flows round a closed system.

Main parts of the cooling system:

• Coolant pump, located in the engine.
• Expansion tank, located in the engine compartment.
• Thermostat, located in the engine
• Cooling fan, located in front of the radiator
• Water cooler, part of the cooling unit (to the far left)
• Engine oil cooler, located in the engine
• Transmission oil cooler, part of the cooling unit (left middle section)
• Intercooler, part of the cooling unit (to the far right)

Engine cooling work as follows:

1. Coolant is circulated through the cylinder head, engine block and
oil cooler by the coolant pump.
2. The thermostat directs the heated coolant back to the coolant
pump or through the radiator.
3. When the coolant is colder than the thermostat opening
temperature the thermostat directs it back through the engine.
When the coolant is warmer than the thermostat opening
temperature the thermostat directs it through the radiator and then
back to the coolant pump.
4. The expansion tank allows the coolant to expand without escaping
from the engine.

1.7.4 Radiator and expansion tank

Radiator and expansion tank, description
Radiator for the engine is located in the cooling unit which is placed
1 behind the engine.

The function of the cooler unit is to cool:

• Engine coolant.
• Transmission oil (cooled in the lower part of the cooler unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
• Charge air (cooled in the upper part of the cooler unit), see also
Intercooler, description, page 1:21.

See also Cooling system, description, page 1:23.

For more information, see supplier documentation, engine.

5
4
3
014763

2
Cooling unit
1. Expansion tank
2. Intercooler
3. Condenser
4. Transmission oil cooler
5. Radiator, engine

Workshop Manual DCF 80-100 VDCF05.01GB

1:24 1 Engine – Cooling fan

1.7.5 Cooling fan

Drive belt, replacement
1 Machine in service position, see section B Safety.

2 Loosen the belt tensioner and lock it with a drift (position 1).
3 Remove the belt from the coolant pump (position 2) first.
4 Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves, and that it is tensioned correctly.

1
014242

1.7.7 Coolant

Coolant, changing
Cooling efficiency is impaired due to deposits in the radiator and in the
engine's cooling ducts. Consequently, the system must always be
cleaned when replacing the coolant.

WARNING
The cooling system is pressurised. Steam or hot fluid
may spurt out.
Risk or scalding or burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before filling.

WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, wear protective
glasses and protective gloves. In the event of skin
contact, wash your hands.

VDCF05.01GB Workshop Manual DCF 80-100

 1 Engine – Coolant 1:25

IMPORTANT
Machines with ECC or AC are equipped with a combined
heating and cooling unit, which can result in a risk of
freezing if the machine is operated without coolant.
Risk of freezing and damage to the heating and cooling
unit!
The electrical connections on the AC compressor must
be disconnected when cleaning the radiator with water
or agents without antifreeze properties.

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

NOTE
Before draining, stop the engine and remove the filler cap.

Workshop Manual DCF 80-100 VDCF05.01GB

1:26 1 Engine – Coolant

Draining
1 Remove the filler cap from the cooling system's expansion tank.

C B A
014058

A Position for coolant reservoir (expansion tank)

B Filling point
C Sight glass

2 Open all drain points. Drain the coolant from the radiator and
engine block using the drainage hose.
The drainage nipples and located on the radiator and on the
right-hand side of the engine block or under the oil cooler.
3 Check that all coolant drains out.

NOTE
There may be deposits inside the tap/plug, which must be
cleaned away, otherwise there is a risk that the coolant may
remain and cause freezing damage.

Let the drainage taps or plugs remain open and make sure that
the heating control is set to full heat while cleaning.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If impurities remain after flushing for a long time, it's possible to
clean with coolant. Otherwise, continue with step Filling point,
page 1:27.

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 1 Engine – Coolant 1:27

Cleaning with coolant

1 Fill the cooling system. Only use the recommended concentrated
coolant, see tab F Technical data.

2 Drain the cooling system after 1-2 days of operation.

NOTE
Drainage should be performed quickly, within 10 minutes,
without the engine being at a standstill for a long time to prevent
dissolved material from re-entering the cooling system.
Remove the filler cap from the expansion tank and possibly a
lower radiator hose to increase the draining speed.

3 Immediately rinse the system very carefully with clean warm water
to prevent dirt from depositing again on the internal surfaces.
Rinse until the outflowing water is completely clean. Check that
the water valve is fully open when cleaning.

4 Should impurities remain after flushing for a long time, it's possible
to clean with coolant, contact Cargotec Service.

NOTE
Only use cleaning agents approved by the engine manufacturer.
Follow the instructions on the packaging carefully.

Filling point
1 When the cooling system is completely free from impurities, close
the drain valves.

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

NOTE
Only use recommended coolant.

2 Fill coolant so that the level is between the MIN and MAX
markings. The engine must not be started until the system has
been bled and filled completely.

3 Start the engine when the system has been completely bled and
filled with coolant. Open any breather valves for a time after
starting, so that any trapped air can escape.
Check that the water valve is fully open in order to bleed the
heating system.

4 Stop the engine after approx. one hour and check the coolant
level, top up if needed.

Workshop Manual DCF 80-100 VDCF05.01GB

1:28 1 Engine – NO (normally open) switch, coolant level

1.7.8 NO (normally open) switch, coolant level

NO (normally open) switch, coolant level, description
The coolant level NO switch is located on the expansion tank.

1.7.10 Engine heater

Engine heater, description

See supplier documentation, engine.

A start-inhibitor function is available as an option coupled with the

engine heater. The function is activated when the heater is running.

VDCF05.01GB Workshop Manual DCF 80-100

1 Engine – Control system, engine 1:29

1.9 Control system, engine

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

Workshop Manual DCF 80-100 VDCF05.01GB

1:30 1 Engine – Start/stop

1.11 Start/stop
1.11.1 Starter motor
Starter motor, description
The starter motor cranks the engine until fuel combustion begins and
the engine starts.

The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by the
engine control unit (D794).

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.6.5 ENGINE, menu 5.

For more information, see supplier documentation, engine.

1.11.2 Stopping device

Stopping device, description
The engines have electrically regulated injectors that stop delivering
fuel when the voltage is cut off, which means that the engine stops.

The engine is stopped by switching off the ignition with the ignition
key lock.

There is a stop button on the engine that can be used in an emergency

to stop the engine, e.g. if the engine cannot be stopped by other
means.

NOTE
The battery disconnector must not be used for emergency stop!

For more information, see supplier documentation, engine.

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

entered via the display before the engine can be started.

An automatic engine shutoff is available as an option, this means

that the engine is shutoff automatically after 3-30 minutes (depending
on the customer setting) irrespective of whether the driver is sitting
in the seat or not. The conditions are that the machine is stationary
and idling.

VDCF05.01GB Workshop Manual DCF 80-100

 2:1

2 Transmission

Contents 2 Transmission
2 Transmission ......................................................................................................2:3
2.1 Controls and instruments ............................................................................... 2:11
2.1.1 Gear selector and multi-function lever....................................................... 2:11
2.2 Torque converter/Clutch system ....................................................................2:12
2.2.1 Flex plates .................................................................................................2:12
2.6 Lubrication system .........................................................................................2:13
2.6.3 Oil cooler ...................................................................................................2:16
2.7 Cooling system ..............................................................................................2:18
2.7.3 Oil cooler ...................................................................................................2:18
2.8 Control system, transmission.........................................................................2:19
2.8.1 Transmission control unit ..........................................................................2:19
2.8.2 Break contact (opening switch) declutch...................................................2:19
2.8.3 Transmission cable harness......................................................................2:19

Workshop Manual DCF 80-100 VDCF05.01GB

2:2

VDCF05.01GB Workshop Manual DCF 80-100

2 Transmission – Transmission 2:3

2 Transmission
Transmission, general
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the transmission's components and systems, refer
to the relevant supplier documentation.

References to supplier documentation are only provided in exceptional

cases. If information about a component is not found, the component
supplier documentation should be used.

Workshop Manual DCF 80-100 VDCF05.01GB

2:4 2 Transmission – Transmission

Transmission, function description

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

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

D793 D795 D797-1

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

4 17

11
3

009864
Pos Explanation Signal description Reference
1 The multi-function lever (S162) Forward, Conn. F: U = 24 Gear selector and multi-function lever,
sends a voltage signal to the KIT V description, page 2:11
control unit (D790-2).
Reverse, Conn. R: U = 24 D1: Diagnostic menu, see section 8 Control
V system, group 8.4.7.2 TRANSM menu 2
2 Control unit KIT (D790-2) transmits Checked by control See section 11 Common electrics, group
the selected direction of travel system, error shown with 11.5.3.11 Control unit KIT (D790-2)
(forward or reverse) on the CAN bus. error code.
3 The transmission's oil pump pumps - -
oil when the engine is running.
4 The transmission's oil filter cleans - -
the oil from impurities.
5 The accelerator pedal transmits a U = 0.5-4.5 V See section 1 Engine, group 1.1.2 Accelerator
signal to Control unit, cab (D790-1). pedal
D5: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE menu 1
6 Control unit, cab (D790-1) transmits Checked by control See section 11 Common electrics, group
the desired throttle application on the system, error shown with 11.5.3.1 Cab control unit (D790-1)
CAN bus. error code.

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Transmission 2:5

Pos Explanation Signal description Reference

7 Control unit KIT (D790-2) sends the Checked by control See section 11 Common electrics, group
selected shifting program on the system, error shown with 11.5.3.11 Control unit KIT (D790-2)
CAN bus. error code.
8 The oil pressure sensors sends a Checked by Control unit, D8: Diagnostic menu, see section 8 Control
voltage signal to the transmission transmission, error shown system, group 8.4.7.10 TRANSM menu 10
control unit (D793) if oil pressure is with error code.
too low.
9 The engine speed and oil Checked by Control unit, D9: Diagnostic menu, See Section 8 Control
temperature sensor (B758/766) transmission, error shown system, group 8.4.7.6 TRANSM, menu 6 and
sends the transmission control unit with error code. 8.4.7.10 TRANSM, menu 10
(D793) a pulse signal with frequency
proportional to engine speed and
a voltage signal proportional to the
transmission oil temperature.
10 The transmission control unit (D793) Checked by Control unit, Control unit transmission, general, page 2:19
supplies voltage to valve block transmission, error shown
transmission control to obtain with error code.
desired function.
11 Solenoid valves for travel direction Checked by Control unit, -
and gear position in valve block transmission, error shown
transmission control activate with error code.
gears in the transmission and the
engine's power is transmitted to the
transmission's output shaft.
12 Sensor, turbine speed (B751) Checked by Control unit, D12: Diagnostic menu, see section 8 Control
sends Control unit, transmission transmission, error shown system, group 8.4.7.6 TRANSM menu 6
(D793) a pulse signal with frequency with error code.
proportional to turbine speed.
13 The drum sensor (B752) sends the Checked by Control unit, D13: Diagnostic menu, see section 8 Control
transmission control unit (D793) transmission, error shown system, group 8.4.7.6 TRANSM menu 6
a pulse signal with frequency with error code.
proportional to drum speed.
14 The output shaft speed sensor Checked by Control unit, D14: Diagnostic menu, see section 8 Control
(B758) sends the transmission transmission, error shown system, group 8.4.7.6 TRANSM menu 6
control unit (D793) a pulse signal with error code.
with frequency proportional to output
shaft speed.
15 The torque converter temperature Checked by Control unit, D15: Diagnostic menu, see section 8 Control
switch (S221) sends the transmission transmission, error shown system, group 8.4.7.10 TRANSM menu 10
control unit (D793) a voltage signal with error code.
if oil temperature in the torque
converter becomes too high.
16 Control unit, transmission (D793) Checked by Control unit, Control unit transmission, general, page 2:19
controls gear shifting according to transmission, error shown
selected shifting program. with error code.
17 The oil cooler cools the transmission - Oil cooler, description, page 2:18
oil. A thermostat senses the oil's
temperature and directs the oil back
to the transmission if the oil is cold.
18 Control unit, transmission (D793) Checked by control Control unit transmission, general, page 2:19
transmits temperature and speed system, error shown with
data on the CAN bus. error code.
19 Control unit KID (D795) shows Checked by control See section 11 Common electrics, group
transmission information in operating system, error shown with 11.5.3.12 KID control unit (D795)
menus. error code.
20 If the signal from the output shaft - D20: Diagnostic menu, see section 8 Control
speed sensor (B758) indicates that system, group 8.4.7.6 TRANSM menu 6
machine speed exceeds the speed
limitation, the transmission control
unit (D793) transmits a engine speed
reduction request on the CAN bus.

Workshop Manual DCF 80-100 VDCF05.01GB

2:6 2 Transmission – Transmission

Pos Explanation Signal description Reference

21 Control unit, engine (D794) reduces - See section 11 Common electrics, group
the engine speed. 11.5.3.10 Engine control unit (D794)
22 If the clutch pedal (S220-1) is U = 24 V See section 9 Frame, body, cab and
pressed down, it sends a voltage accessories, group 9.1 Controls and
signal to the cab control unit instruments.
(D790-1).
D22: Diagnostic menu, see section 8 Control
system, group 8.4.7.1, TRANSM menu 1
23 Control unit, cab (D790-1) transmits Checked by control See section 11 Common electrics, group
declutch drive on the CAN bus. system, error shown with 11.5.3.1 Cab control unit (D790-1)
error code.
24 Normally closed (NC) switch, Brake pressure above Break contact (opening switch) declutch,
disengagement (S220-2) sends 0.2 MPa: description, page 2:19
the frame control unit (D797-1) a
Conn 1, U = 24 V D24: Diagnostic menu, see section 8 Control
voltage signal if brake pressure
system, group 8.4.7.1, TRANSM menu 1
is high enough to allow drive Conn 2, U = 24 V
disengagement.
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
25 The frame control unit (D797-1) Checked by control See section 11 Common electrics, group
transmits disengagement approved system, error shown with 11.5.3.2 Frame control unit (D797-1)
on the CAN bus. error code.
26 Control unit, transmission (D793) Checked by Control unit, Control unit transmission, general, page 2:19
supplies voltage to valve block transmission, error shown
transmission control so that drive is with error code.
declutched.
27 If the operator leaves the driver's U = 24 V Section 9 Frame, body, cab and accessories,
seat, the operator-in-seat sensor group 9.3.14 Operator-in-seat sensor
(S230) sends a voltage signal to the
D27: Diagnostic menu, see section 8 Control
cab control unit (D790-1).
system, group 8.4.7.1 TRANSM menu 4
28 The cab control unit (D790-1) Checked by control See section 11 Common electrics, group
transmits go to neutral on the CAN system, error shown with 11.5.3.1 Cab control unit (D790-1)
bus. error code.
29 The transmission control unit (D793) Checked by Control unit, Control unit transmission, general, page 2:19
supplies voltage to valve block transmission, error shown
transmission control so that the drive with error code.
is put in neutral three seconds after
the operator leaves the driver's seat.

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Transmission 2:7

Shifting transmission, function description

7 9 11 13 15
RSP
25 5
Fwd 2 Rev 1/3
6
8
26 10 12 14 16
18
VFS 1/3
3 4
17
28
27
19
2

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

008240
29 20 21 22 23 24

Pos Explanation Signal description Reference

1. Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2. The transmission's oil pump 1 supplies 92.1 l/min at 2420 rpm -
the transmission with control pressure for
control of the transmission.
3. The oil filter cleans the oil. - -

4. The bypass valve in the filter bracket leads Opening pressure: 390 -
the oil past the filter if the resistance through kPa
the filter becomes too high.
5. The pressure governor releases pressure Opening pressure: -
to the torque converter if the pressure 2500-2900 kPa
becomes too high.
6. The pressure reducer reduces the feed 1200 kPa -
pressure to servo pressure.
7. Solenoid valve neutral position (RSP) - Diagnostic menu, see section 8 Control
(Y6066) controls Valve spool neutral system, group 8.4.7.7 TRANSM, menu 7
position.
8. Valve spool neutral position opens or closes - -
to allow control pressure to the transmission.
9. Solenoid valve drive forward (Y630) controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster drive forward. system, group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
10. Pressure booster forward increases the 0-2000 kPa -
pressure and pressurises Drive clutch
forward.
11. Solenoid valve gear 2 (Y6069) controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster gear 2. system, group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
12. Pressure booster gear 2 increases the 0-3000 kPa -
pressure and feeds Valve spool gear
selection 2.
13. Solenoid valve drive reverse controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster drive reverse. system, group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
14. Pressure booster reverse increases the 0-2000 kPa -
pressure and pressurises Drive clutch
reverse.

Workshop Manual DCF 80-100 VDCF05.01GB

2:8 2 Transmission – Transmission

Pos Explanation Signal description Reference

15. Solenoid valve 1/3 (Y6067) controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster gear 1/3. system, group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
16. Pressure booster gear 1/3 increases the 0-2000 kPa -
pressure and feeds Valve spool gear
selection 1/3 as well as.
17. Contact drive sends signal to the control - -
unit to verify that drive clutches for travel
direction and gear selection are activated
when solenoid valve neutral position (RSP)
(Y6066) is activated.
18. Solenoid valve VFS 1/3 (Y6075) controls 0-1000 mA Diagnostic menu, see section 8 Control
servo pressure to Valve spool gear selection system, group 8.4.7.7 TRANSM, menu 7
1/3.
19. Valve spool gear selection 1/3 pressurises 0-2000 kPa -
Drive clutch gear 1 or Drive clutch gear 3.
20. Drive clutch forward locks transmission in 0-2000 kPa -
forward drive when the clutch is pressurised.
21. Drive clutch gear 2 locks transmission 0-2000 kPa -
in gear position 2 when the clutch is
pressurised.
22. Drive clutch reverse locks transmission in 0-2000 kPa -
reverse drive when the clutch is pressurised.
23. Drive clutch gear 1 locks transmission 0-2000 kPa -
in gear position 1 when the clutch is
pressurised.
24. Drive clutch gear 3 locks transmission 0-2000 kPa -
in gear position 3 when the clutch is
pressurised.
25. The safety valve leads the oil back to the Opening pressure: 850 -
sump if the pressure to the torque converter kPa
becomes too high.
26. The torque converter transmits the engine's - -
power to the transmission.
27. The transmission oil cooler cools the oil. - -

28. The torque converter bypass valve leads the Opening pressure: 400 -
oil past the torque converter if the pressure kPa
becomes too high.
29. The oil is distributed to different lubrication - -
points in the transmission.

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Transmission 2:9

Transmission, component location

3 4
14 7
2
1
12
6 13

15
8
16
9
17
10

014736
19 18 11
1. Valve block transmission control 11. Oil filter transmission
2. Radiator connection (out from transmission) 12. Radiator inlet
3. Oil pump transmission 13. Radiator outlet
4. Power take-off 14. Transmission oil cooler
5. Cooling unit 15. Radiator connection (from radiator to sump)
6. Thermostat 16. Temperature monitor torque converter (S221)
7. Breather filter transmission 17. Sensor turbine speed (B751)
8. Sensor, drum rpm (B752) 18. Sensor rpm output shaft (B758)
9. Engine speed and oil temperature sensor (B758/766) 19. Output shaft
10. Sensor oil pressure

Workshop Manual DCF 80-100 VDCF05.01GB

2:10 2 Transmission – Transmission

3 4 5
2

11

10 9 8

014041
1. Accelerator pedal (B690) 7. Declutch pedal (S220-1)
2. Multi-function lever (S162) 8. Control unit, transmission (D793)
3. Control unit KIT (D790-2) 9. Control unit, engine (D794)
4. Control unit, KID (D795) 10. Frame control unit (D797-1)
5. Control unit, cab (D790-1) 11. Switch (NC), disengagement (S220-2)
6. Sensor operator in seat (S230)

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Controls and instruments 2:11

Engine and transmission, replacement

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

2.1 Controls and instruments

2.1.1 Gear selector and multi-function lever
Gear selector and multi-function lever, description
Selection of direction travel is made with the gear selector and
F
multi-function lever.

Selecting direction of travel:

• F - Forward
• N - Neutral
• R - Reverse

The switch is supplied voltage by and sends signals to the KIT control
unit (D790-2).
002209

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

Workshop Manual DCF 80-100 VDCF05.01GB

2:12 2 Transmission – Torque converter/Clutch system

2.2 Torque converter/Clutch system

2.2.1 Flex plates
Flex plates, changing
1 Machine in service position, see section B Safety.
Before the flex plate can be replaced, the engine and transmission
must be split, see Engine and transmission, replacement, page
2:11

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

3 Fit the transmission, see Engine and transmission, replacement,
page 2:11.
4 Before the machine is put into operation, the transmission must be
calibrated; see Transmission, calibration, page 2:19.
007774

Mounting of flex plate (transmission alternative TE17)

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Lubrication system 2:13

2.6 Lubrication system

Lubrication system, description
The transmission lubrication system has the following function:
• Lubricate gear wheels and bearings
• Apply the clutches in the transmission
• Cool down the torque converter and the transmission
• Clean the oil of any impurities with the oil filter.

During operation of the engine, the oil pump draws oil from the
transmission's oil sump through a strainer, and it then pumps it through
the oil filter to a control valve.

The control valve supplies oil at the correct pressure to the

transmission's valve housing to activate the clutch plates for
FORWARD or REVERSE and gear 1, 2 or 3. The clutch plates require
just a small amount of the oil flow supplied by the pump. The remainder
of the oil is pumped through the torque converter circuit to the oil cooler
and returns to the transmission for lubrication.

See also supplier documentation, transmission.

Oil and oil filter transmission, changing

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

NOTE
The transmission must not be over-filled!

1 Operate and warm up the transmission oil.

2 Machine in service position, see section B Safety.

3 Place a receptacle under the transmission.

4 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.

NOTE
Make sure that the seal washer for the drain plug is fitted as well.

Draining transmission oil

Workshop Manual DCF 80-100 VDCF05.01GB

2:14 2 Transmission – Lubrication system

5 Clean the area around the oil filter.

6 Change oil filter.
Lubricate the O-ring on the new oil filter with transmission oil.
Tighten to contact and then another two-thirds of a turn.
7 When the transmission oil has drained, fit the drain plug.

NOTE
Make sure that the seal washer for the drain plug is fitted as well.

004331

Oil filter transmission

8 Remove the transmission dipstick and fill new transmission oil

through the dipstick's hole to the marking for low level on the
dipstick.
For volume and quality, see section F Technical data.
9 Turn the main current on and start the engine and allow the engine
to idle for at least two minutes.
10 Check that the transmission oil drain plug is sealed.
11 Check the transmission oil level with the engine running at idle and
top up to the marking for low level.

A
B
008156

A Position for filler orifice and level checking

B Oil dipstick and filler orifice

12 Operate and warm up the transmission so that the display shows

an oil temperature of approx. 60-65 ºC. Use the oil temperature
operating menu to check transmission oil temperature.
a
13 Check the oil level. Fill to the MAX mark.
000356

b 14 Calibrate the transmission; see Transmission, calibration, page

2:19.
Operating menu, oil temperature
a Transmission oil temperature
b Hydraulic oil temperature

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Lubrication system 2:15

Oil level, checking

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

The transmission's oil filler pipe and dipstick are located under the
engine hood.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 82-93 ºC in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the oil dipstick before checking.

NOTE
The oil dipstick is long. Wear gloves.

2 Fill transmission oil (position B) if required (for volume and grade,

see section F Technical data).
A
Fill - wait a moment - check the oil dipstick.
B
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil. Other fluids or
particles in the transmission oil means a risk of transmission
damage.
008156

A Position for filler orifice and level checking

B Oil dipstick and filler orifice

Workshop Manual DCF 80-100 VDCF05.01GB

2:16 2 Transmission – Oil cooler

2.6.3 Oil cooler

Oil cooler, description
The transmission oil is cooled in the left middle section of the cooling
1 unit.

A temperature-controlled bypass valve, which only acts on the

transmission oil cooling circuit, is located in a pipe on the underside
of the cooler (engine side). The valve closes when the oil starts to
reach operating temperature. This means that the oil reaches normal
operating temperature more quickly.

For more information, see supplier documentation, transmission.

5
4
3
014763

2
Cooling unit
1. Expansion tank
2. Intercooler
3. Condenser
4. Transmission oil cooler
5. Radiator, engine

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Oil cooler 2:17

Thermostat transmission oil cooler, replacement

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

1 Machine in service position, see section B Safety.

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

3 Loosen the cover plug and remove the thermostat.

4 Check the O-ring and the spring in the bottom, replace as
necessary.
5 Install the new thermostat, and the cover plug.

IMPORTANT
It is very important that the thermostat is turned with
the temperature bulb facing out as shown.
014550

6 Fill with transmission oil; see Oil level, checking, page 2:15.
Thermostat transmission oil cooler for engine option
TAD762VE 7 Start the engine and check for leaks.
8 Check the transmission oil level, see Oil level, checking, page
2:15.

Workshop Manual DCF 80-100 VDCF05.01GB

2:18 2 Transmission – Cooling system

2.7 Cooling system

2.7.3 Oil cooler
Oil cooler, description
See Oil cooler, description, page 2:16.

VDCF05.01GB Workshop Manual DCF 80-100

 2 Transmission – Control system, transmission 2:19

2.8 Control system, transmission

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

2.8.1 Transmission control unit

Control unit transmission, general
See section 11 Common electrics, group 11.5.3.9 Control unit,
transmission and Supplier documentation, transmission.

2.8.2 Break contact (opening switch) declutch

Break contact (opening switch) declutch, description
Break contact (opening switch) declutch detects whether the wheel
brakes are pressurised. The break contact (opening switch) is located
on the distribution block for the brake system above the drive axle's
differential.

The sensor can be checked via the diagnostic menu. See section 8
Control system, group 8.4.7.1 TRANSM, menu 1.

1
10
2
1
3
3
4
5
5
9 6
8 7
009865

1. Connection brake cooling, return from wheel

brake
2. Connection brake cooling, return to radiator and
tank
3. Connection brake cooling, to wheel brake
4. Connection brake cooling, from accumulator
charging valve
5. Connection brake cylinder, to wheel brake
6. Connection brake pressure, from brake valve
7. NC switch, disengagement (S220)
8. Make-contact (closing switch), brake light
(S216)
9. Measuring outlet, brake pressure
10. Measuring outlet, back pressure brake cooling

2.8.3 Transmission cable harness

Transmission cable harness, description
See section E Schematics.

Workshop Manual DCF 80-100 VDCF05.01GB

2:20

VDCF05.01GB Workshop Manual DCF 80-100

 3:1

3 Power transmission

Contents 3 Power transmission

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

Workshop Manual DCF 80-100 VDCF05.01GB

3:2

VDCF05.01GB Workshop Manual DCF 80-100

3 Power transmission – Power transmission 3:3

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

Propeller shaft, replacement

1 Machine in service position, see section B Safety.

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

gearbox.

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

4 Fit the propeller shaft's attaching bolts.
Tightening torque: 98 Nm (oiled bolt). Retighten the attaching
bolts after 50 operating hours.
005193

Workshop Manual DCF 80-100 VDCF05.01GB

3:4 3 Power transmission – Drive axle

3.3 Drive axle

Drive axle, general
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the drive axle's components and systems, refer to
the relevant supplier documentation.

References to supplier documentation are only provided in exceptional

cases. If information about a component is not found, the component
supplier documentation should be used.

Drive axle, replacement

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

1 Remove the mast, see section 7 Load handling, group 7.2

Lifting/lowering.

2 Park the machine with blocks behind the steering wheels.

3 Depressurise the hydraulic systems, See section B Safety.
4 Turn the start key to position 0 and switch off the main power.

5 Insert wedges between the steering axle and the frame.

VDCF05.01GB Workshop Manual DCF 80-100

 3 Power transmission – Drive axle 3:5

6 Detach the hydraulic hoses (position 1) and cable harness

(position 2) from the distribution block.

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

004501
2

1. Hydraulic hoses
2. Cables

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

3
004505

3. Cover, parking brake

8 Loosen the lock nut (position 4) and screw in the screw (position
5), this compresses the brake spring. Screw until the brake pads
release from the brake disc. Refit the cover on the parking brake
(position 3).
6
9 Detach the hydraulic hose (position 6) from the parking brake.

NOTE
5 Plug all connections immediately to protect the hydraulic system
from impurities.
4
004506

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

Workshop Manual DCF 80-100 VDCF05.01GB

3:6 3 Power transmission – Drive axle

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

Securing the propeller shaft.

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

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

Lifting machine

14 Remove the bolts that secure the drive axle in the frame.
15 Lift away the drive axle.

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

Attaching bolts drive axle

VDCF05.01GB Workshop Manual DCF 80-100

3 Power transmission – Drive axle 3:7

16 Undo the hydraulic hoses on the drive axle.

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

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

18 Transfer the parking brake union to the new axle.

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

Workshop Manual DCF 80-100 VDCF05.01GB

3:8 3 Power transmission – Drive axle

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

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

24 Lower the frame toward the drive axle.

25 Insert the new screws securing the drive axle in the frame. Tighten
to 1530 Nm (oiled screw).
26 Install the drive wheels on the new axle.
27 Rustproof the bolts with suitable paint.

28 Connect hydraulic hoses (position 1) and cable harness (position

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

VDCF05.01GB Workshop Manual DCF 80-100

 4:1

4 Brakes

Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1 Controls and instruments .................................................................................4:3
4.1.1 Brake pedal .................................................................................................4:3
4.3 Power-assisted brake system ..........................................................................4:5
4.3.1 Hydraulic oil pump.......................................................................................4:8
4.3.2 Hydraulic oil filter .......................................................................................4:10
4.3.3 Accumulator charging valve ...................................................................... 4:11
4.3.4 Accumulator ..............................................................................................4:14
4.3.5 Brake valve ...............................................................................................4:18
4.3.6 Drive axle block .........................................................................................4:22
4.3.7 Break contact (opening switch) brake pressure ........................................4:23
4.3.8 Make-contact (closing switch) brake lights................................................4:25
4.3.9 Wheel brakes ............................................................................................4:27
4.3.10 Pipes and hoses........................................................................................4:29
4.5 Parking brake system ....................................................................................4:30
4.5.1 Hydraulic oil pump.....................................................................................4:33
4.5.2 Hydraulic oil filter .......................................................................................4:33
4.5.3 Solenoid valve parking brake ....................................................................4:33
4.5.4 Parking brake unit .....................................................................................4:34
4.5.5 Break contact (opening switch) parking brake ..........................................4:37
4.5.6 Pipes and hoses........................................................................................4:37
4.8 Temperature control, cleaning and hydraulic oil.............................................4:38
4.8.1 Hydraulic oil tank .......................................................................................4:38
4.8.3 Hydraulic oil pump.....................................................................................4:38
4.8.4 Accumulator charging valve ......................................................................4:38
4.8.5 Drive axle block .........................................................................................4:39
4.8.6 Wheel brakes ............................................................................................4:39
4.8.8 Thermal bypass valve ...............................................................................4:39
4.8.9 Cooling fan ................................................................................................4:39
4.8.10 Sensor hydraulic oil temperature...............................................................4:39
4.8.11 Breather filter hydraulic oil tank .................................................................4:39
4.8.12 Hydraulic oil filter .......................................................................................4:39
4.8.13 Pipes and hoses........................................................................................4:39
4.8.14 Hydraulic oil...............................................................................................4:39

Workshop Manual DCF 80-100 VDCF05.01GB

4:2

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Brakes 4:3

4 Brakes
4.1 Controls and instruments
4.1.1 Brake pedal

Brake pedal, checking and adjustment

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

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

Stop screw for adjusting clearance between brake pedal

and brake valve. (The illustration shows a loose brake
pedal.)

4 Lubricate the pedal hinge with "EP2" universal grease.

5 Check that the rubber pad on the brake pedal is intact and that the
tread pattern is not worn away. Replace if necessary.
6 Check the brake valve; see Brake valve, checking, page 4:19.

Lubrication points, brake pedal. (The illustration shows

a loose brake pedal.)

Brake pedal, replacement

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

1 Switch off the engine and switch off the system voltage.

2 Depressurise the brake and hydraulic systems, see section B

Safety.

3 Detach the brake valve from the brake pedal.

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

Workshop Manual DCF 80-100 VDCF05.01GB

4:4 4 Brakes – Brake pedal

4 Remove the panel around the steering wheel shaft.

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

5 Detach the steering valve from the pedal assembly.

Secure the steering valve on the cab's underside. Remove the
steering valve's attaching bolts. Pull down the valve slightly so that
the steering axle releases from the steering valve.
6 Detach the steering wheel shaft from the brake pedal.
Undo the bolts and pull the steering wheel shaft up slightly so that
the brake pedal can be removed.
7 Detach the declutch pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedal's attaching bolt and lift away the brake
pedal.
9 Transfer the pedal rubber to the new pedal.

Mounting of steering wheel shaft and steering valve in 10 Fit the new brake pedal.
pedal assembly. Fit the pedal and fit the pedal's attaching bolts.
11 Connect the steering valve to the brake pedal.
12 Connect the brake valve to the brake pedal.
13 Fit the clutch pedal to the brake pedal.

14 Close the drain valve on the accumulator charging valve.

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

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

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Power-assisted brake system 4:5

4.3 Power-assisted brake system

Power-assisted brake system, function
description

5
B
13 P
T
D790-2
D11
D797-1
10, 12 8 C
Pa
11

C 9 D9
D8
4 Pa
3
C ACC
7
B
P
6
2

008059
B
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil See the pressure plate on the Hydraulic oil pump, description, page 4:8
from the oil tank. left-hand frame beam.
2 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description, page 4:39
3 The accumulator charging Charging: P = 20.5±0.5 MPa Accumulator charging valve, description, page
valve directs oil to charging of 4:11
Cooling: P < 0.1 MPa
accumulators or through the brake
system's cooling circuit.
4 The accumulators store oil See the pressure plate on the Accumulator, description, page 4:14
pressure. left-hand frame beam.
5 The brake valve directs pressure - Brake valve, description, page 4:18
from the accumulators to the brake
cylinders proportional to pressing
of the pedal.
6 The brake cylinders compress the See the pressure plate on the Wheel brakes, description, page 4:27
discs in the brake unit. left-hand frame beam.
7 The wheel brakes brake the - Wheel brakes, description, page 4:27
machine.

Workshop Manual DCF 80-100 VDCF05.01GB

4:6 4 Brakes – Power-assisted brake system

Pos Explanation Signal description Reference

8 Make-contact (closing switch), Brake pressure above Make-contact (closing switch) brake lights,
brake light (S216) closes the circuit 0.2 MPa: description, page 4:25
when the brake cylinders are
Conn. 1, U = 24 V D8: Diagnostic menu, see section 8 Control
pressurised.
system, group 8.4.5.4 HYD, menu 4
Conn. 2, U = 24 V
Brake pressure below
0.2 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
9 Brake pressure NC switch (S204) Brake pressure above Brake pressure NC switch, description, page
opens the circuit if the pressure in 11.5 MPa: 4:23
the accumulators is low.
Conn. 1, U = 24 V D9: Diagnostic menu, see section 8 Control
system, group 8.4.5.4 HYD, menu 4
Conn. 2, U = 24 V
Brake pressure below
11.5 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
10 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics, group 11.5.3.2
transmits the brake light request on error shown with error code. Frame control unit (D797-1)
the CAN bus.
11 The brake light lamps (H411L and U = 24 V Section 9 Frame, body, cab and accessories,
H411R) are activated by the frame group 9.6.4 Brake lights
control unit (D797-1).
D11: Diagnostic menu, see section 8 Control
system, group 8.4.2.8 LIGHTS, menu 8
12 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics, group 11.5.3.2
transmits a warning about low error shown with error code. Frame control unit (D797-1)
brake pressure on the CAN bus.
13 Control unit KIT (D790-2) activates Controlled by control system, Section 11 Common electrics, group 11.5.3.11
Warning lamp brake pressure. error shown with error code. KIT control unit (D790-2)

Hydraulic diagram, see section E Schematics group 10 Common

hydraulics, Basic machine

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Power-assisted brake system 4:7

Power-assisted brake system, component

positions

4
1 2
5 6

3 8
9

12

008061
11 10

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

2. Control unit KIT (D790-2) 8. Distribution block drive axle
3. Brake valve 9. Make-contact (closing switch) brake light (S216)
4. Frame control unit (D797-1) 10. Hydraulic oil filter
5. Wheel brakes 11. Hydraulic oil pump
6. Accumulator charging valve 12. Accumulators

Workshop Manual DCF 80-100 VDCF05.01GB

4:8 4 Brakes – Hydraulic oil pump

4.3.1 Hydraulic oil pump

Hydraulic oil pump, description
The brake system has a gear pump with fixed displacement. The
1
2 hydraulic oil pump sits in the rear part on the right main pump. The
pump generates hydraulic power, which is stored in the accumulators
for brake force to the power-assisted brake and parking brake. It also
generates the oil flow used for cleaning and cooling. The switchover
between power generation and flow is regulated by the accumulator
charging valve, see Accumulator charging valve, description, page
4:11.

For description of how a gear pump works, see section 10 Common

hydraulics, group 10.4.1 Gear pump with fixed displacement.
3
4
009967

1. Hydraulic oil pump for load handling

2. Hydraulic oil pump for quick-lift:
3. Hydraulic oil pump for brake system, cooling
and filtration.
4. Hydraulic oil pump for steering and load handling

Hydraulic oil pump, checking

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

Checking the pump pressure

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

2 Machine in service position, see section B Safety.

3 Depressurise the hydraulic systems, See section B Safety.

4 Connect a pressure gauge (0-25 MPa) to the pump pressure

measuring outlet on the accumulator charging valve.
5 Start the engine and run it at idle.
008048

Measuring outlet, pump pressure

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Hydraulic oil pump 4:9

6 Close the drain valve on the accumulator charging valve and

check the pump pressure during charging.
During charging the pressure should increase to 20.5±1.0 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
7 Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine speed.
8 Turn off engine.

008049
9 Depressurise the hydraulic systems, See section B Safety.
10 Remove the pressure gauge and fit the protective cap on the
Close the accumulator charging valve measuring outlet.
11 Close the drain valve on the accumulator charging valve.

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

Checking the accumulator charging

12 Depressurise the hydraulic systems, See section B Safety.

13 Connect a pressure gauge (0-25 MPa) to the accumulator

pressure measuring outlet on the accumulator charging valve.
14 Start the engine and run it at idle.
008050

Measuring outlet, accumulator pressure

15 Close the drain valve on the accumulator charging valve.

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

16 Check that the pressure increases slowly to 20.5±1.0 MPa.

17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 15.5±0.5 MPa.
008049

18 Depressurise the hydraulic systems, See section B Safety.

19 Remove the pressure gauge and fit the protective cap on the
Close the accumulator charging valve
measuring outlet.
20 Close the drain valve on the accumulator charging valve.

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

Workshop Manual DCF 80-100 VDCF05.01GB

4:10 4 Brakes – Hydraulic oil filter

Hydraulic oil pump, replacement

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

The hydraulic oil pump for brake system, cooling and filtration and the
load handling pump are replaced as a unit. See section 10 Common
hydraulics group 10.4.1 Gear pump with fixed displacement.

4.3.2 Hydraulic oil filter

Hydraulic oil filter, general
See Hydraulic oil filter, description, page 4:39.

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Accumulator charging valve 4:11

4.3.3 Accumulator charging valve

Accumulator charging valve, description
The accumulator charging valve distributes the oil from the hydraulic
3 4 5 6
oil pump between pressure storage and cooling of the wheel brakes.
The accumulator charging valve is located to the left of the frame in
the space by the gearbox.

The accumulator charging valve stores pressure by directing the oil to

the accumulators. The wheel brakes are cooled by oil being directed
to the drive axle cooling circuit and then on to the brake system cooler.

The accumulator charging valve prioritises charging of the

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

The drain valve (position 11) is used to relieve the pressure in the
accumulators to the tank. The valve opens a connection between the
accumulators and the wheel brake's cooling circuit. The oil is drained
through the wheel brake to the tank.

There is a measuring outlet to measure the accumulator pressure

2 1 13 12 11 10 9 8 7 (position 5) and pump pressure (position 4) on the accumulator
charging valve. The pressures are individual to each machine and
are on the pressure plate on the left-hand frame member, see section
10 Common hydraulics. Also fitted on the accumulator charging
valve are: Solenoid valve parking brake (position 6), Break contact
(opening switch) brake pressure (position 9) and Break contact
(opening switch) parking brake (position 7).
• Solenoid valve parking brake, description, page 4:33
• Make-contact (closing switch) brake lights, description, page 4:25
• Break contact (opening switch) parking brake, description, page
4:37
009867

1. Safety valve
2. Connection from pump (P)
3. Connection, wheel brake (T)
4. Measuring outlet, pump pressure (P)
5. Measuring outlet, accumulator pressure (M)
6. Solenoid valve parking brake (Y642)
7. Break contact (opening switch), parking brake
(GHB) (S260)
8. Connection, accumulators (ACC)
9. Brake pressure break contact (opening switch)
(LB) (S204)
10. Connection, parking brake caliper (HB)
11. Drain valve
12. Main valve, charging
13. Pressure limiting valve

Workshop Manual DCF 80-100 VDCF05.01GB

4:12 4 Brakes – Accumulator charging valve

Accumulator charging, checking and adjustment

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

1 Machine in service position, see section B Safety.

2 Check accumulator charging, see Hydraulic oil pump, checking,

page 4:8.

3 If necessary, adjust the accumulator charging pressure on the

pressure limiting valve.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
4 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the valves and check the max. pressure again.
5 Repeat steps 3 and 4 until the pressure is correct.
008245

Adjusting screw accumulator charging pressure

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Accumulator charging valve 4:13

Accumulator charging valve, replacement

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

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

3 Mark up hydraulic hoses and electric cables.

4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator charging
valve.
Remove the parking brake valve for easier access.

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

6 Remove the accumulator charging valve.

7 Transfer the connection adapters and sensors to the new
accumulator charging valve.
8 Fit the new valve.
9 Connect the hoses to the accumulator charging valve in
008244

accordance with the marking.

Attaching bolts, accumulator charging valve NOTE

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

10 Fit the parking brake valve and parking brake NO switch.

11 Connect the wiring to the accumulator charging valve.

12 Close the drain valve on the accumulator charging valve.

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

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

Check that the hydraulic connections are sealed tightly.
14 Check the charging and switching function, see Accumulator
charging, checking and adjustment, page 4:12.
009868

Workshop Manual DCF 80-100 VDCF05.01GB

4:14 4 Brakes – Accumulator

4.3.4 Accumulator
Accumulator, description
The accumulators store pressure so that there is a pressure reserve
in the event of engine or brake system malfunction. The brake
system has two parallel-connected accumulators placed on the frame
member on the left-hand side of the machine.

The accumulators are of the diaphragm type. Each accumulator

is divided into two compartments by a diaphragm. One side of
the diaphragm is pressurised by nitrogen gas. The other side is
pressurised by the hydraulic oil, which compresses the nitrogen gas.

At the top of the accumulator, there is a connection for checking

nitrogen gas pressure (and for filling nitrogen gas using special filling
equipment).

When the accumulator is charged with hydraulic oil the diaphragm

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

Pressurised oil from the accumulator is used for the service and
parking brake systems and for supplying the servo hydraulics'
009869

reducing valve (see section 4 Brakes and section 7 Load handling).

Brake system accumulators NOTE

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

Accumulator, checking

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

NOTE
Special tools for checking the accumulators can be ordered from
Cargotec. The following describes the procedure without special
tools.

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

3 The accumulators can be tested with separate test equipment or

in the machine. Primarily, separate test equipment should be used
since it is faster and more accurate.
Test equipment can be ordered from Cargotec.
• Test with test equipment: continue with step 4.
• Test in machine: continue with step 6.

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Accumulator 4:15

Checking with test equipment

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

M Pa

009870

Pressure plate, gas pressure brake accumulators

Checking in the machine

3
2 6 Detach one of the accumulators from the distribution block. Plug
1 the connection on the distribution block with a plug that can
withstand high pressure. Plug the connection on the accumulator
to protect against impurities.
009871

1. Clamp
2. Screw
3. Distribution block

Workshop Manual DCF 80-100 VDCF05.01GB

4:16 4 Brakes – Accumulator

7 Connect a pressure gauge (0-25 MPa) to the accumulator

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

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

10 Check that the plug seals properly.

11 Turn off engine.
12 Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
004810

When the pressure reaches approx. 10 MPa the pressure must

decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is switched off
then the accumulator does not have any precharge pressure. This
indicates internal leakage and the accumulator must be replaced.
If the pressure can be reduced slowly to a pressure below 10
MPa then the precharge pressure is too low and the accumulator
must be replaced or handed over to authorised personnel for
maintenance.
13 Depressurise the hydraulic systems, See section B Safety.
14 Mark up and disconnect the tested accumulator. Plug the
connections. Connect one of the other accumulators to the
distribution block.
15 Repeat steps 8 - 14 until all accumulators have been checked.
16 Depressurise the hydraulic systems, See section B Safety.
Installation and final checking
17 Connect both accumulators to the distribution blocks. If necessary,
replace or fill deficient accumulators.

NOTE
Check that the seals are intact, clean and in the correct position.

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

19 Close the drain valve on the accumulator charging valve so that
the accumulators are charged.

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

20 Check that the accumulators' connections are sealed tightly.

21 When the accumulators are fully charged, switch off the engine
and turn the start key to position I.

22 Check that at least 8 brake applications (pedal depressions) can

be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must be
switched on.

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Accumulator 4:17

Accumulator, replacement

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

1 Machine in service position, see section B Safety.

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

3 Depressurise the hydraulic systems, See section B Safety.

4 Detach the accumulator's clamp and remove the bolt.

3
2 5 Detach the accumulator from the distribution block.
1
NOTE
Hold the block firmly so that the other accumulator does not
work loose.

6 Bend the clamp away and remove the accumulator.

009871

7 Fit the new accumulator.

1. Clamp NOTE
2. Screw Check that the seal is intact, clean and fitted in the correct
position.
3. Distribution block
8 Secure the accumulator's clamp and tighten the bolt.

9 Close the drain valve on the accumulator charging valve.

10 Turn on the main electric power and start the engine.
11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking, page
4:14 steps 18-19.
009868

Workshop Manual DCF 80-100 VDCF05.01GB

4:18 4 Brakes – Brake valve

4.3.5 Brake valve

Brake valve, description
3 The brake valve, which is located on the underside of the cab
underneath the brake pedal, controls the hydraulic pressure to the
2 brakes. A lever transfers pedal force to the valve.
1
The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion
to brake pressure. This provides optimum pedal responsiveness and
increased safety as the operator senses if no brake pressure is being
built up (no resistance in the pedal).

009872

1. Inlet from accumulator [P]

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

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Brake valve 4:19

Brake valve, checking

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

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

reaches operating temperature, at least 50 ºC.

2 Machine in service position, see section B Safety.

3 Depressurise the hydraulic systems, See section B Safety.

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

brake pressure on the distribution block on the front axle.
5 Close the drain valve on the accumulator charging valve.

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

6 Start the machine and run it at idle until the accumulators are
charged and the accumulator charging valve changes to cooling.
7 Press down the pedal completely and read off the pressure.
Compare with the pressure plate on the left-hand frame member.
8 Turn off engine.

9 Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
the pressure plate and must not decrease from this value for 15
seconds.
10 Release the pedal, the brake pressure must decrease to 0 MPa
immediately. Otherwise the brake valve is not sealed and could
cause the brakes to remain applied and then overheat during
operation.
Replace the brake valve if it is not sealed.
11 Depressurise the hydraulic systems, See section B Safety.
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
13 Close the drain valve on the accumulator charging valve.

NOTE
Check that the accumulator drain valve is fully closed and
009873

tighten the lock ring.

Workshop Manual DCF 80-100 VDCF05.01GB

4:20 4 Brakes – Brake valve

Brake valve, replacement

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

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

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

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

009875 4 Secure the brake valve under the cab.

5 Remove the brake valve's attaching bolt.

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

NOTE
Remember the spacer ring.

9 Connect the hydraulic hoses to the brake valve in accordance

B with the marking.

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

10 Lubricate and adjust the brake pedal, see Brake pedal, checking
004795

and adjustment, page 4:3.

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Brake valve 4:21

11 Close the drain valve on the accumulator charging valve.

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

12 Turn on the main electric power and start the engine. Let the
engine run at idle speed.
13 Test the brakes a couple of times.
14 Check that the brake valve's connections are sealed tightly.
15 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
bleeding, page 4:28.

009868

Workshop Manual DCF 80-100 VDCF05.01GB

4:22 4 Brakes – Drive axle block

4.3.6 Drive axle block

Drive axle block, description
The drive axle block distributes oil flow and brake pressure to the right
1 and left-hand wheel brakes. The drive axle block is fitted on a bracket
10
2 above the drive axle differential.
1
3 The drive axle block has a measuring outlet for brake pressure and
for measuring back pressure in the disc brake's cooling circuit.
3
4
The drive axle block has a bypass valve which leads oil directly from
5 the cooling circuit intake to the cooling circuit return if the resistance
5
in the axle becomes too great. This protects the wheel brake seals,
9 6 e.g. when the oil is cold.

8 7 There are two contacts in the drive axle block: brake light NO switch
(216), see Make-contact (closing switch) brake lights, description,
page 4:25 and disengagement NO switch, see section 2 Transmission,
group 2.8.2 Normally closed (NC) switch, disengagement.
009876

1. Connection brake cooling, return from wheel

brake
2. Connection brake cooling, return to radiator
3. Connection brake cooling, to wheel brake
4. Connection brake cooling, from accumulator
charging valve
5. Connection brake cylinder, to wheel brake
6. Connection brake pressure, from brake valve
7. Make-contact (closing switch), declutch (S220)
8. Make-contact (closing switch), brake light
(S216)
9. Measuring outlet, brake pressure
10. Measuring outlet, back pressure brake cooling

VDCF05.01GB Workshop Manual DCF 80-100

4 Brakes – Break contact (opening switch) brake pressure 4:23

4.3.7 Break contact (opening switch) brake

pressure
Brake pressure NC switch, description
Break contact (opening switch) brake pressure (S204) detects the
pressure in the accumulators. The break contact (opening switch) is
fitted on the accumulator charging valve on the lifting beam in front
of the gearbox in the engine compartment.

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

Break contact (opening switch) brake pressure (S204) voltage fed by

Frame control unit (D797-1). When the pressure increases above the
cut-off pressure, the voltage signal to the Frame control unit (D797-1)
is cut.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.4 HYD, menu 4.
009877

Brake pressure NC switch, adjusting

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

1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 ºC.

2 Machine in service position, see section B Safety.

3 Depressurise the hydraulic systems, See section B Safety.

Workshop Manual DCF 80-100 VDCF05.01GB

4:24 4 Brakes – Break contact (opening switch) brake pressure

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

accumulator pressure on the accumulator charging valve.
5 Close the drain valve on the accumulator charging valve.

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

6 Start the engine and fully charge the accumulators (the

accumulator charging valve changes to cooling).
7 Stop the engine and turn the start key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be
approx. 11.5 MPa.
004810

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

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

NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.

11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
13 Depressurise the hydraulic systems, See section B Safety.
14 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
15 Close the drain valve on the accumulator charging valve.

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

VDCF05.01GB Workshop Manual DCF 80-100

4 Brakes – Make-contact (closing switch) brake lights 4:25

4.3.8 Make-contact (closing switch) brake lights

Make-contact (closing switch) brake lights,
description
Make-contact (closing switch) brake lights controls brake light
activation when the machine brakes. The switch is fitted on the drive
axle block which is fitted on a bracket above the drive axle differential.

Make-contact (closing switch) brake light (S216) is supplied voltage

by and sends a voltage signal to Frame control unit (D797-1). When
the pressure increases above the closing pressure, a voltage signal is
sent to Frame control unit (D797-1).

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

009878

Make-contact (closing switch) brake light, checking

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

1 Operate and warm up the machine until the hydraulic oil reaches
operating temperature, at least 50 ºC.

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

3 Brake and check that the brake light is switched on.

4 Depressurise the hydraulic systems, See section B Safety.

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

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

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

7 Start the engine.

Workshop Manual DCF 80-100 VDCF05.01GB

4:26 4 Brakes – Make-contact (closing switch) brake lights

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

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

000144
DECLUTCH PRESSURE X 9 Depress the brake pedal slowly until the brake light is switched on
or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status should change and the brake light should be switched
on when the pressure is approx. 0.2 MPa.
10 Turn off engine.
11 Depressurise the hydraulic systems, See section B Safety.
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
13 Close the drain valve on the accumulator charging valve.

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

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Wheel brakes 4:27

4.3.9 Wheel brakes

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

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

009879

The wheel brakes have two main sections - disc pack and brake
1 2 cylinder. The disc pack performs the braking. The brake cylinder
presses the discs in the disc pack together during braking.
000016

Wheel hub and brake, cross-section

1. Disc pack
2. Brake cylinder

Workshop Manual DCF 80-100 VDCF05.01GB

4:28 4 Brakes – Wheel brakes

Wheel brakes, bleeding

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

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

1 Machine in service position, see section B Safety.

2 Position a ring spanner on the bleed nipple and connect a

transparent hose to the bleed nipple.
Route the other end of the hose down into a receptacle.
3 Start the machine and depress the brake pedal, keep the pedal
depressed.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.

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

5 Close the bleed nipple.

Bleed nipple, brake cylinder, on top of the drive axle at
the wheel hub's inner short side (left-hand side). 6 Move the spanner and hose and repeat steps 1-4 on the other side.
7 Check the oil level in the brake system, fill if necessary.

Wheel brake, replacement

See supplier documentation, drive axle.

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Pipes and hoses 4:29

4.3.9.1 Disc pack

Disc pack, description

The disc pack consists of several thin coated metal discs fixed
alternately to the wheel brake housing and to the hub reduction
housing. The discs are mounted on splines, which allows them to
move laterally.

Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.

Braking takes place by means of the brake cylinder pressing together

the discs. This creates friction between the discs that are fixed to the
axle and those fixed to the hub reduction.

000008

Disc pack

4.3.9.2 Brake cylinder

Brake cylinder, description

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

The space between the seal rings is pressurised through a channel

in the wheel brake housing. The pressure moves the metal ring
sideways and compresses the disc pack.
000007

Brake cylinder

4.3.10 Pipes and hoses

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

Workshop Manual DCF 80-100 VDCF05.01GB

4:30 4 Brakes – Parking brake system

4.5 Parking brake system

Parking brake system, function description

D5

5
6 12
D790-1 D790-2

D797-1
7 11
C D8 D10
4
8
Pa 10 9
C ACC

3
H
P
T
2

008060
B
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil from P = 21±1 MPa Hydraulic oil tank, description, page 4:38
the hydraulic oil tank.
Hydraulic oil pump, description, page 4:8
2 The hydraulic oil filter cleans dirt from the - Hydraulic oil filter, description, page 4:39
oil.
3 The accumulator charging valve directs Charging: P = Accumulator charging valve, description,
oil to charging of accumulators or through 20.5±0.5 MPa page 4:11
the brake system's cooling circuit.
Cooling: P < 0.1 MPa
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description, page 4:14
frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and
the parking brake. accessories, group 9.1 Controls and
Conn. 1, U = 24 V
instruments
The switch uses two signals, one for
Conn. 7, U = 0 V
applied and one for released parking D5: Diagnostic menu, see section 8
brake. Both signals must be correct to Switch in home position: Control system, group 8.4.5.5 HYD, menu
enable release of the parking brake. 5
Conn. 1, U = 0 V
Conn. 7, U = 24 V
6 The cab control unit (D790-1) transmits Controlled by control Section 11 Common electrics, group
Activate parking brake on the CAN bus. system, error shown with 11.5.3.1 Cab control unit (D790-1)
error code.

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Parking brake system 4:31

Pos Explanation Signal description Reference

7 The frame control unit (D797-1) activates U = 24 V Solenoid valve parking brake, description,
the parking brake solenoid valve (Y642). page 4:33
D7: Diagnostic menu, see section 8
Control system, group 8.4.5.5 HYD, menu
5
8 Solenoid valve parking brake (Y642) acts Pump pressure Solenoid valve parking brake, description,
on the valve slide which drains pressure page 4:33
in the parking brake's brake caliper to
tank.
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description, page 4:34
and the spring applies the parking brake.
10 The parking brake NC switch (S200) Applied parking brake: Break contact (opening switch) parking
closes the circuit when the pressure brake, description, page 4:37
Conn. 1, U = 24 V
increases.
D10: Diagnostic menu, see section 8
Conn. 2, U = 0 V
Control system, group 8.4.5.5 HYD, menu
Released parking brake: 5
Conn. 1, U = 24 V
Conn. 2, U = 24 V
11 The frame control unit (D797-1) transmits Controlled by control Section 11 Common electrics, group
Parking brake applied on the CAN bus. system, error shown with 11.5.3.2 Frame control unit (D797-1)
error code.
12 Control unit KIT (D790-2) activates Controlled by control Section 9 Frame, body, cab and
indicator light, parking brake (508). system, error shown with accessories, group 9.1 Controls and
error code. instruments

Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics, Basic machine

Workshop Manual DCF 80-100 VDCF05.01GB

4:32 4 Brakes – Parking brake system

Parking brake system, component positions

1 4
2 5 6

12

008062
11 10 9 8

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

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

VDCF05.01GB Workshop Manual DCF 80-100

4 Brakes – Hydraulic oil pump 4:33

4.5.1 Hydraulic oil pump

Hydraulic oil pump, general
See Hydraulic oil pump, description, page 4:8.

4.5.2 Hydraulic oil filter

Hydraulic oil filter, general
See Hydraulic oil filter, description, page 4:39.

4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
Solenoid valve parking brake (Y642) activates the parking brake.
The solenoid valve is fitted on the accumulator charging valve, which
is fitted on the lifting beam in front of the gearbox in the engine
compartment, see Accumulator charging valve, description, page
4:11.

The solenoid valve opens a connection between the accumulators

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

The solenoid valve is supplied with voltage by the frame control unit
(D797-1) at activation.
009880

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.5 HYD, menu 5.

Solenoid valve parking brake, checking

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

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

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

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

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

Workshop Manual DCF 80-100 VDCF05.01GB

4:34 4 Brakes – Parking brake unit

4.5.4 Parking brake unit

Parking brake unit, description
3 1 The parking brake unit keeps the machine stationary when parked.
2
The parking brake unit is fitted on the drive axle input shaft between
the propeller shaft and drive axle.

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

NOTE
If the hydraulic pressure in the feed circuit drops, a warning is
activated before the pressure drops so low that the parking brake
is applied. If the parking brake is applied while the machine is in
motion, the brake disc and brake pads must be replaced.
009881

1. Protective cap over adjusting screw

2. Parking brake unit
3. Brake disc of parking brake

Parking brake unit, checking and adjustment

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

1 Start the engine and run up hydraulic pressure until the

accumulators are fully charged and the accumulator charging
valve switches to cooling.

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

3 Release the parking brake.

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

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

VDCF05.01GB Workshop Manual DCF 80-100

 4 Brakes – Parking brake unit 4:35

6 Remove the cover from the brake caliper.

Check that there is no oil inside the cover.

7 Loosen the lock nut.

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

NOTE
To avoid turning the adjusting screw as well it must be held still
when tightening the lock nut.

11 Refit the cover to the caliper.

12 Test the function of the parking brake.

4.5.4.1 Parking brake caliper

Brake caliper, description

The brake caliper has a spring section and a hydraulic section. The
1 2 3 4 5 spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine is
braked if a serious fault arises.
000020

1. Brake pads
2. Release cylinder
3. Thrust spring
4. Slackening screw
5. Adjusting washer

Workshop Manual DCF 80-100 VDCF05.01GB

4:36 4 Brakes – Parking brake unit

4.5.4.2 Parking brake pads

Brake pads, description

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

Brake pads, replacement (Kessler drive axle)

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

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

Safety.

2 Remove the cover from the brake caliper.

3 Loosen the lock nut.

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

VDCF05.01GB Workshop Manual DCF 80-100

4 Brakes – Break contact (opening switch) parking brake 4:37

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

NOTE
The bolt does not need to be removed.

7 Remove the parking brake pads.

8 Clean the brake disc with methylated spirit.
9 Fit new parking brake pads.
10 Press back the attaching bolt.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjustment, page 4:34.

4.5.4.3 Parking brake disc

Brake disc, description

The brake disc is fitted on the drive axle input shaft. The drive axle's
gear ratio amplifies the braking force.

4.5.5 Break contact (opening switch) parking

brake
Break contact (opening switch) parking brake,
description
Break contact (opening switch) parking brake (S200) detects whether
the parking brake is applied or released. The break contact (opening
switch) is fitted on the accumulator charging valve, which is fitted on
the lifting beam in front of the transmission in the engine compartment,
see Accumulator charging valve, description, page 4:11.

Break contact (opening switch) parking brake (S200) senses the

pressure in the parking brake circuit. When the pressure is so high
that the parking brake is released, the sensor opens an electric circuit.
This is used to indicate that the parking brake is released.

Break-contact (opening switch) parking brake light (S200) is supplied

voltage by and sends a voltage signal to Frame control unit (D797-1).
When the pressure increases above the cut-off pressure, the voltage
signal to the Frame control unit (D797-1) is cut.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.5 HYD, menu 5.
009882

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

4.5.6 Pipes and hoses

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

Workshop Manual DCF 80-100 VDCF05.01GB

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

4.8 Temperature control, cleaning

and hydraulic oil
Temperature control, cleaning and hydraulic oil,
function description
C C

4
P T

2 5
3

002611
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil from See pressure plate on left Hydraulic oil pump, description, page 4:8
the hydraulic oil tank. frame beam.
Section 10 Common hydraulics, group
10.3.1 Tank
2 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description, page 4:39
3 The accumulator charging valve directs Charging: P = Accumulator charging valve, description,
oil to charging of accumulators or 20.5±0.5 MPa page 4:11
through the brake system's cooling
Cooling: P < 0.1 MPa
circuit.
4 The oil cools the wheel brake. - Wheel brakes, description, page 4:27
5 The bypass valve in the distribution - Drive axle block, description, page 4:22
block leads oil past the drive axle if the
back pressure through the wheel brake
is too great.

Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics, Basic machine

Temperature control, cleaning and hydraulic oil,

component positions
Hydraulic oil pump, hydraulic oil filter, accumulator
charging valve, drive axle block, wheel brakes
See Power-assisted brake system, component positions, page 4:7.

4.8.1 Hydraulic oil tank

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

4.8.3 Hydraulic oil pump

Hydraulic oil pump, description
See Hydraulic oil pump, description, page 4:8.

4.8.4 Accumulator charging valve

Accumulator charging valve, description
See Accumulator charging valve, description, page 4:11.

VDCF05.01GB Workshop Manual DCF 80-100

4 Brakes – Drive axle block 4:39

4.8.5 Drive axle block

Drive axle block, description
See Drive axle block, description, page 4:22.

4.8.6 Wheel brakes

Wheel brake, description
See Wheel brakes, description, page 4:27 and supplier documentation,
drive axle.

4.8.8 Thermal bypass valve

Thermal bypass valve, description
See section 10 Common hydraulic, group 10.6.5 Radiator bypass
valve.

4.8.9 Cooling fan

Cooling fan, description
See section 10 Common hydraulics, group 10.6.3 Cooling fan.

4.8.10 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
See section 10 Common hydraulics, group 10.6.4 Hydraulic oil
temperature sensor.

4.8.11 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
See section 10 Common hydraulics, group 10.6.6 Breather filter,
hydraulic oil tank.

4.8.12 Hydraulic oil filter

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

4.8.13 Pipes and hoses

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

4.8.14 Hydraulic oil

Hydraulic oil, description
See section 10 Common hydraulics, group 10.6.8 Hydraulic oil.

Workshop Manual DCF 80-100 VDCF05.01GB

4:40

VDCF05.01GB Workshop Manual DCF 80-100

 5:1

5 Steering

Contents 5 Steering
5 Steering ...............................................................................................................5:3
5.2 Power assisted system ....................................................................................5:3
5.2.1 Hydraulic oil pump.......................................................................................5:4
5.2.2 Priority valve................................................................................................5:6
5.2.3 Steering valve .............................................................................................5:8
5.2.4 Steering cylinder .......................................................................................5:10
5.2.5 Steering axle cradle .................................................................................. 5:11
5.2.6 Link arm ....................................................................................................5:12
5.2.7 Wheel spindle............................................................................................5:12
5.2.8 Wheel hub .................................................................................................5:12
5.2.9 Shuttle valve..............................................................................................5:12
5.2.13 Pipes and hoses........................................................................................5:12

Workshop Manual DCF 80-100 VDCF05.01GB

5:2

VDCF05.01GB Workshop Manual DCF 80-100

 5 Steering – Steering 5:3

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

2
PP P
C
CF LS
T
5
P

LS T L R
3

1
6

008053
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil to the See the pressure plate on Section 10 Common hydraulics, group 10.4.2
priority valve. the left-hand frame beam. Axial piston pump with variable displacement
2 The priority valve prioritises pressure Checked by control Priority valve, description, page 5:6
feed to the control valve over working system, error shown with
hydraulics. The priority valve also sends error code.
control signals to the hydraulic oil pump.
3 Shuttle valve control selects the Checked by control Section 10 Common hydraulics, group
strongest load signal to the hydraulic oil system, error shown with 10.5.3 Shuttle valve
pump if hydraulic functions are activated error code.
at the same time as the steering wheel
is turned.
4 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accessories,
the steering valve\qs input shaft. group 9.1 Controls and instruments
5 The steering valve pumps pressurised - Steering valve, description, page 5:8
oil to the steering cylinder and transmits
a load signal to the main pump.
6 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:10

Hydraulic diagram, see section E Schematics group 10 Common

hydraulics, Basic machine

Workshop Manual DCF 80-100 VDCF05.01GB

5:4 5 Steering – Hydraulic oil pump

Power-assisted steering system, component

positions

4 6
5 7

014828
1
Hydraulic components
1. Hydraulic oil pump for steering and load handling 5. Steering valve
2. Shuttle valve 6. Control valve mini-wheel/joystick control
3. Priority valve 7. Steering axle with steering cylinder
4. Connection terminal, return oil

5.2.1 Hydraulic oil pump

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

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 5 Steering – Hydraulic oil pump 5:5

Control pressure, checking

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

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

reaches operating temperature, 50 ºC.

2 Machine in service position, see section B Safety.

3 Connect the pressure gauge to the measuring outlet on the

hydraulic oil pump for steering and load handling.
4 Start the engine and increase engine speed to approx. 1200 rpm.

009885

Measuring outlet on hydraulic oil pump for steering and

load handling

5 Turn the steering wheel fully and read pump pressure during the
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate.
6 Turn the start key to position 0 and switch off the main power.
7 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
009886

Workshop Manual DCF 80-100 VDCF05.01GB

5:6 5 Steering – Priority valve

5.2.2 Priority valve

Priority valve, description
1 2 The priority valve divides the oil flow from the hydraulic oil pump for
steering and load handling so that there is always oil to the steering
valve. The residual flow goes to working hydraulics or servo circuit.

The priority valve is load sensing and pilot pressure compensating.

Load sensing means that the valve adapts the control signal to the
steering valve's consumption. Pilot pressure compensating means
that the priority valve compensates for the pressure drop between the
priority valve and steering valve via a separate line.

The priority valve has a built-in pressure limiter on the load signal.
3
6 The pressure limiter maximises the load signal's pressure.
5 4
009884

1. Feed pressure from hydraulic oil pump (P)

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

Priority valve, replacement

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

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic system, see section B Safety.

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

VDCF05.01GB Workshop Manual DCF 80-100

 5 Steering – Priority valve 5:7

1 2 4 Mark up and detach the hydraulic hoses from the priority valve.

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

5 Remove the priority valve attaching bolts.

6 Disconnect the priority valve from control valve lift and lower.
3 7 Remove the priority valve.
6 4
5 8 Transfer the connection adapters to the new priority valve.

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

9 Connect the new priority valve to control valve lift and lower.

CAUTION
009884

1. Feed pressure from hydraulic oil pump (P)

Do not tighten the hydraulic connection between
2. Pilot pressure (PP), pressure drop to control priority valve and collection block before all other
valve connections and attaching bolts are fitted.
3. Pressure to load handling control valve (EF) Stresses in the priority valve may result in incorrect
4. Load signal from control valve (LS) function.
5. Tank draining (T)
6. Pressure to control valve (CF) 10 Fit the priority valve attaching bolts.
11 Connect the hydraulic hoses to the priority valve in accordance
with the marking.
12 Check that control valve lift and lower is not jammed against the
priority valve.
13 Tighten the hydraulic connection between priority valve and
collection block.
14 Start the engine and check that the hydraulic connections at the
priority valve are sealed.
15 Check the control pressure, see Control pressure, checking, page
5:5.

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5:8 5 Steering – Steering valve

5.2.3 Steering valve

Steering valve, description
The steering valve is a “closed centre, non-reaction valve” with load
signal connection to the priority valve.

The load signal generates load-dependent control of oil flow from the
1 priority valve to the steering valve. "Closed centre" means that the
steering valve is closed in its neutral position. This is necessary so
that signal pressure can be connected to the steering valve.
2 The steering valve consists of a gear pump and a distribution valve.
5
When the steering wheel is turned, oil flows from the main pump over
4 3 the gear pump to the distribution valve, which directs the oil to the
steering cylinder. The gear pump ensures that the oil flow fed to the
cylinder is proportional to the steering wheel's turning angle.

The steering valve contains double shock and anti-cavitation valves.

The shock valves protect the hydraulics against pressure spikes which
can arise from impacts on the steering wheels. The anti-cavitation
valves (non-return valves) protect against vacuum on the piston's rear
side, which can lead to cavitation.
009887

Steering valve, replacement

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

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

2 Depressurise the hydraulic systems, See section B Safety.
3 Turn the start key to position 0 and switch off the main power.

1. Water valve
2. Steering valve

VDCF05.01GB Workshop Manual DCF 80-100

 5 Steering – Steering valve 5:9

4 Detach the steering valve from the brake pedal.

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

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

6 Remove the steering valve.

7 Transfer the connection adapters to the new steering valve.

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

8 Connect the hydraulic hoses to the steering valve in accordance

with the marking.

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

9 Connect the new steering valve to the brake pedal.

Position the steering valve and check that the steering wheel
shaft's splines enter straight in the steering valve's slot. Fit the
attaching bolts.
10 Turn on the main electric power and start the engine.
11 Check that the connections on the steering valve are sealed tightly.
12 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.

Workshop Manual DCF 80-100 VDCF05.01GB

5:10 5 Steering – Steering cylinder

5.2.4 Steering cylinder

Steering cylinder, description
The steering cylinder acts on the wheels via the link arms. The
1 2 3 steering cylinder is a double-acting hydraulic cylinder.

4
009888

1. Steering cylinder
2. Shaft
3. Lock screw
4. Fastening screw (locked with locking fluid)

Steering cylinder, replacement

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

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

2 Machine in service position, see section B Safety.

3 Depressurise the brake and hydraulic systems, see section B

Safety.

4 Detach the link arms from the steering cylinder.

VDCF05.01GB Workshop Manual DCF 80-100

 5 Steering – Steering axle cradle 5:11

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

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

6 Remove the steering cylinder's attaching bolts.

7 Replace the steering cylinder. Lift the steering cylinder aside.

NOTE
The steering cylinder is heavy, use lifting equipment.

1. Hydraulic connection 8 Support the new steering cylinder so that the holes in the attaching
bolts are lined up directly opposite the holes in the steering axle.
2. Attaching bolt
9 Fit and lubricate the steering cylinder attaching bolts. Tighten the
bolts crosswise in steps until 680 Nm is achieved.
10 Transfer parts to the new steering cylinder.

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

11 Fit the link arms to the steering cylinder.

12 Connect the hydraulic hoses to the steering cylinder.

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

13 Close the drain valve on the accumulator charging valve. See

section B Safety.
14 Start the engine and check for leaks.

Hydraulic cylinders, repairs

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

5.2.5 Steering axle cradle

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

Workshop Manual DCF 80-100 VDCF05.01GB

5:12 5 Steering – Link arm

5.2.6 Link arm

Link arm, description
The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.

The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels
then they must be replaced.

The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
1

008854
1. Link arm

5.2.7 Wheel spindle

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

5.2.8 Wheel hub

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

5.2.9 Shuttle valve

Shuttle valve, description
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.

5.2.13 Pipes and hoses

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

VDCF05.01GB Workshop Manual DCF 80-100

 6:1

6 Suspension

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

Workshop Manual DCF 80-100 VDCF05.01GB

6:2

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 6 Suspension – Suspension 6:3

6 Suspension
6.2 Suspension
Bushing steering axle mounting, changing

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

1 Machine in service position, see section B Safety.

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

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

4 Attach hoisting equipment to the rear of the machine and take up

the slack so that the steering axle's mounts are relieved.

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

5 Remove the pins holding the steering axle.

6 Lift the machine so that the frame is off the steering axle.
7 Support the machine under the frame.
8 Move the steering axle so that the mountings can be accessed.

NOTE
If necessary, disconnect the cable harness for the sensors on
the steering axle.
009890

The illustration shows rear mounting

Workshop Manual DCF 80-100 VDCF05.01GB

6:4 6 Suspension – Steering axle cradle

9 Remove the washers that hold the bushing in place.

2
10 Press out the bushing.
1 11 Clean the bearing surfaces on the steering axle.
12 Press in the new bushing. Grease the bushing to facilitate
installation.
13 Fit the washers that hold the bushing in place.
14 Move the steering axle into place under the frame.
15 Lubricate and fit the pins at the steering axle's mounts.
3
16 Remove the lifting equipment from the machine.
4

010121
1. Steering axle mounting
2. Rubber bushing
3. Washers
4. Screw

6.2.1 Steering axle cradle

Steering axle cradle, description
The steering axle is pendulum suspended with a double-acting
1 2 3 4 5 6
steering cylinder. The design comprises a minimum of moving parts
to minimise service points and simplify maintenance. The frame
suspension comprises maintenance-free parts.
008047

Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. Spindle bolt / - bearing

Steering axle cradle, replacement

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

1 Clean the steering axle and its surrounding area.

VDCF05.01GB Workshop Manual DCF 80-100

6 Suspension – Steering axle cradle 6:5

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

3 Depressurise the hydraulic systems, See section B Safety.

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

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

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

7 Support the machine's rear section.

8 Detach the hydraulic hoses from the steering cylinder.

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

9 Remove the pins holding the steering axle.

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

11 Lift out the steering axle.

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

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

position.

13 Lift the steering axle into place under the frame.

14 Remove the support under the frame.

15 Lower the rear section of the machine.

16 Fit the pins at the steering axle mountings.

17 Connect the hydraulic hoses to the steering cylinder.

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

18 Remove the lifting equipment from the machine.

Workshop Manual DCF 80-100 VDCF05.01GB

6:6 6 Suspension – Wheel spindle

6.2.2 Wheel spindle

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

3
2

4
5
1 6
8 7

9
009780

11 10
1. Wheel spindle
2. Seal ring
3. Bearing (upper)
4. Protective ring
5. Seal ring
6. Bearing (lower)
7. Circlip
8. Shim
9. Bearing cage
10. Screw
11. Grease nipple

Spindle bolt bearing, replacement

1 Machine in service position, see section B Safety.

2 Raise the machine under the steering axle at the wheel in

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

VDCF05.01GB Workshop Manual DCF 80-100

6 Suspension – Wheel spindle 6:7

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

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

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

bearing into the steering axle cradle. Use a pipe of a suitable

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

NOTE
The correct number of shims have been used when it takes at least
200 Nm to move the bearing arrangement to move laterally. If it
takes more than 400 Nm for the bearing arrangement to move, it is
too hard and the number of shims must be corrected.

21 Lubricate the wheel spindle bearings via the grease nipples.

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

23 Connect the link arm to the wheel spindle.

24 Fit the wheel.

Workshop Manual DCF 80-100 VDCF05.01GB

6:8 6 Suspension – Wheel hub

25 Remove the support and lower the steering wheel.

26 Test-operate the machine and test the steering. Check also that
the machine feels stable when driving straight ahead.

6.2.3 Wheel hub

Wheel hub, description
The wheel hub holds the wheel in place and allows the wheel to rotate.
3 2
1
4
5
6

7
8
9
10 11
008595

1. Wheel hub
2. Wheel bolt
3. Wheel nut
4. Hub cap
5. Spacer
6. Nut
7. Washer
8. Bearing
9. Screw
10. Bearing
11. Seal ring

Wheel bearing, replacement

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

VDCF05.01GB Workshop Manual DCF 80-100

 6 Suspension – Wheel hub 6:9

3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nut. Handle it as
environmentally hazardous waste.

6 Secure the hub with a lifting strap.

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

7 Bend up the locking washer's tabs, remove the lock nut and
locking washer.
8 Tension the lifting equipment so that the hub is unloaded.
9 Remove the hub nut.

10 Lift the hub out from the spindle.

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

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6:10 6 Suspension – Wheel hub

11 Remove the inner bearing from the wheel spindle.

12 Remove the seal from the hub.

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

NOTE
Fit the outer races with the larger diameter outward.

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

NOTE
Turn the seal correctly.

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

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 6 Suspension – Wheel hub 6:11

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

19 Fit the hub on the wheel spindle.

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

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

22 Tighten the bearing nut in the following stages.

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

Workshop Manual DCF 80-100 VDCF05.01GB

6:12 6 Suspension – Wheel hub

23 Apply grease onto the locking washer and fit it.

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

25 Fill the bearing casing with grease and fit it.

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

VDCF05.01GB Workshop Manual DCF 80-100

6 Suspension – Tyres and rims 6:13

6.3 Tyres and rims

Tyres and rims, safety

DANGER
Always block the wheels on the side of the axle that
is not going to be worked on before positioning the
jack. Always secure the jack to prevent it from sliding
out of position.
Fully deflate the tyre before removal. Otherwise the
conical ring and locking clips can loosen and shoot
out when the pressure is changed. With double wheel
fitting both tyres must be fully deflated!
The air should always be released via the valve. If this
is not possible - drill a hole in the tread to deflate.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflating
or inflating. The conical ring and locking clips can
loosen and shoot out when the pressure is changed.
Never fit damaged tyres or rims.
It is prohibited to repair rims with welding.
It is prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximum wheel loads
and travel speeds are not exceeded. For this reason it
is not permitted to change tyre dimension, tyre make,
tyre type, rim type, or rim make without approval from
Cargotec.

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6:14 6 Suspension – Tyres and rims

CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the
wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace the
spacer rings, with crushing injuries as a result.
When fitting drive wheels, ensure that the clamps clamp
straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to fit or remove rim
components. Instead, use a lead, brass or plastic
mallet.
Keep the tyre pressures at the prescribed level.
Insufficient tyre pressure impairs stability and reduces
the machine's capacity.
Remove stuck objects such as crushed glass, pieces
of wood, metal filings, etc.
Check if tyre wear is abnormal. This could indicate a
mechanical fault. Rectify faults immediately and change
damaged tyres.

VDCF05.01GB Workshop Manual DCF 80-100

 6 Suspension – Tyres 6:15

6.3.1 Tyres
Tyres, description
The tyres are the point of contact between the machine
and the ground, and they absorb unevenness and provide
suspension.
The drive axle is subject to major forces during operation.
If each tyre's rolling circumference differs, the stresses on
the drive axle increase. For this reason it is important that
the tyres on the drive axle have equal wear and correct air
pressure.
Spare and replacement tyres must be from a manufacturer
approved by Cargotec.

009893
009892

Front wheels Rear wheels

Tyres, changing

DANGER
Changing tyres is complicated and dangerous work.
EXTREME DANGER!
Leave tyre work to authorised personnel/tyre company.

The rims must be checked when tyres are changed. See Maintenance
manual DCF 80-100.

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6:16 6 Suspension – Rim

6.3.2 Rim
Rim, description
1 2 3 4 The rim is split to make it possible to fit a tyre. The rim consists of
the following parts.
• Rim
• Rim bead seat
• Rim edge
• Lock ring

5
009899

1. Rim
2. Lock ring
3. Rim edge
4. Tapered rim
5. Wheel nut
6. Wheel bolt

VDCF05.01GB Workshop Manual DCF 80-100

 6 Suspension – Nut, washer and clamp 6:17

6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
1 2 3 4 The rim is attached to the wheel hub with nuts.

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

5
009899

1. Rim
2. Lock ring
3. Rim edge
4. Tapered rim
5. Wheel nut
6. Wheel bolt

Workshop Manual DCF 80-100 VDCF05.01GB

6:18 6 Suspension – Nut, washer and clamp

Wheel bolt, replacement

1 Machine in service position, see section B Safety.

2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel; see Maintenance manual DCF
80-100.

4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.

VDCF05.01GB Workshop Manual DCF 80-100

 7:1

7 Load handling

Contents 7 Load handling

7 Load handling .....................................................................................................7:3
7.1 Controls and instruments .................................................................................7:5
7.1.1 Control levers ..............................................................................................7:5
7.1.2 Switch, lock twistlock/lock tongue ...............................................................7:7
7.1.3 Switch, spreading 20\q-40\q........................................................................7:7
7.1.4 Switch, stop at 30\q .....................................................................................7:8
7.1.13 Switch, automatic spreading .......................................................................7:8
7.2 Lift and lower....................................................................................................7:9
7.2.1 Hydraulic oil pump..................................................................................... 7:11
7.2.2 Servo filter .................................................................................................7:12
7.2.3 Pressure reducer.......................................................................................7:12
7.2.4 Accumulator servo circuit ..........................................................................7:13
7.2.5 Control valve, lift and tilt ............................................................................7:14
7.2.6 Shuttle valve..............................................................................................7:16
7.2.7 Lift cylinder ................................................................................................7:16
7.2.8 Sensor hydraulic pressure lift cylinder.......................................................7:16
7.2.9 Mast ..........................................................................................................7:18
7.2.10 Mast position sensor .................................................................................7:27
7.2.11 Trolley........................................................................................................7:28
7.2.12 Valve block quick-lift ..................................................................................7:35
7.2.13 Pipes and hoses........................................................................................7:35
7.4 Side shift ........................................................................................................7:36
7.4.1 Hydraulic oil pump.....................................................................................7:37
7.4.2 Control valve, attachment .........................................................................7:38
7.4.3 Side shift cylinder ......................................................................................7:42
7.4.4 Shuttle valve..............................................................................................7:42
7.4.5 Trolley........................................................................................................7:43
7.4.6 Valve block, main pump relief....................................................................7:46
7.4.7 Relief valve, attachment ............................................................................7:46
7.4.8 Pipes and hoses........................................................................................7:46
7.5 Spreading (positioning) ..................................................................................7:47
7.5.1 Hydraulic oil pump.....................................................................................7:53
7.5.2 Control valve, attachment .........................................................................7:53
7.5.3 Spreading cylinder ....................................................................................7:54
7.5.4 Spreader beam .........................................................................................7:55
7.5.5 Main beam, side lift attachment.................................................................7:59
7.5.6 Position sensor, spreading ........................................................................7:69
7.5.7 Buzzer, automatic spread 20'-40' ..............................................................7:70
7.5.8 Pipes and hoses........................................................................................7:70
7.7 Tilt ..................................................................................................................7:71
7.7.1 Hydraulic oil pump.....................................................................................7:73
7.7.2 Accumulator ..............................................................................................7:73
7.7.3 Pressure reducer.......................................................................................7:73
7.7.4 Servo filter .................................................................................................7:73
7.7.5 Control valve, lift and tilt ............................................................................7:73
7.7.6 Load retention valve ..................................................................................7:74
7.7.7 Tilt cylinder ................................................................................................7:74
7.7.8 Mast ..........................................................................................................7:75
7.7.9 Pipes and hoses........................................................................................7:75
7.8 Levelling.........................................................................................................7:76
7.8.1 Hydraulic oil pump.....................................................................................7:77
7.8.2 Control valve, attachment .........................................................................7:77
7.8.3 Levelling cylinder.......................................................................................7:79
7.8.4 Trolley........................................................................................................7:79
7.8.5 Valve block, main pump relief....................................................................7:79

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7:2 6 Suspension – Nut, washer and clamp

7.8.6 Pipes and hoses........................................................................................7:79

7.9 Load carrier....................................................................................................7:80
7.9.1 Twistlocks ..................................................................................................7:80
7.9.2 Lifting hook ................................................................................................7:93
7.10 Other functions.............................................................................................7:105
7.10.1 Container counter....................................................................................7:105

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Load handling 7:3

7 Load handling
Position sensor

3
1
4

009906
The illustration depicts a machine with a twistlock attachment
1. Sensor, hydraulic pressure in the lift cylinder (B768-L1), see
Sensor hydraulic pressure lift cylinder, description, page 7:16.
2. Mast position sensor (B7211-2), see Position sensor,
adjusting, page 7:4.
3. Sensor, alignment
(Twistlock B7203L and B7203R), see Alignment sensor,
checking and adjusting, page 7:89,
(Lifting hook B7203LL, B7203LU-2, B7203RL and
B7203RU-2), see Alignment sensor, checking and adjusting,
page 7:103.
4. Sensor, locked twistlocks/lock tongues (B7205LL and
B7205RL), see Twistlocks sensor, checking and adjusting,
page 7:91 or Lock tongue sensor, checking and adjusting,
page 7:104.
5. Detection sensor, upper container (ultrasound) for attachment
with lifting hook (B7203LU and B7203RU), see Detection
sensor, upper container, checking, page 7:103.
6. Damping sensor (B769L, B769R, B777L and B777R), see
Position sensor, adjusting, page 7:4.

Workshop Manual DCF 80-100 VDCF05.01GB

7:4 7 Load handling – Load handling

Position sensor, adjusting

1 Machine in service position, see section B Safety.

2 Check that the sensor in question is free of damage and dirt.

3 Check that the distance between the sensor and the indicator is
5±1 mm.

C-C
5±1 mm
4 Adjust if necessary.

009632
5±1 mm

Adjusting position sensor - indicator

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Controls and instruments 7:5

7.1 Controls and instruments

7.1.1 Control levers
Control levers for electric servo, description
The load handling functions are controlled with fingertip-controlled
linear levers.

The control levers are supplied voltage by and send a signal to the
cab control unit (D790-1).
a. Lift/lower (R8071-P1).
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
The lowering speed can only be varied through lever movement -
d engine speed has no impact.
c
b b. Tilt (R8072-P2).
a
IN - pull the lever backwards.
e OUT - push the lever forwards.
c. Side shift (R8073-P3).
LEFT - move lever forward.
RIGHT - pull the lever backwards.
It is not possible to use side shift on the side lift attachment if the
attachment is in its max or min position.
d. Levelling (R8075-1-P5) .
RIGHT side up - push lever forwards.
LEFT side up - pull lever backwards.
e. Emergency stop switch
f. Opening of locked twistlocks/lock tongues, attachment (S1002)
Pull the switch sideways.

f
008110

Workshop Manual DCF 80-100 VDCF05.01GB

7:6 7 Load handling – Control levers

Control lever, description

Lift and lower

2 3
1
4 The control lever (S815) is used to control the mast and attachment.
The lever sends voltage signals to the Cab control unit (D790-1).

5 The control lever has four potentiometer-controlled functions and

six on/off functions.
6
Lift and lower
7 Lifting/lowering are controlled by moving the control lever
forward (lower - position 10) or rearward (lift - position 12). See
8 Lifting/lowering, function description, page 7:9.

12 9 The signal can be checked from the diagnostic menu, see section 8
009711 Control system, group 8.4.8.1 ELSERV, menu 1.

11 Spreading (positioning)
10
1. Not used When the switch is pressed at position 5, spreading out is activated.
When the switch is pressed at position 4, spreading in is activated.
2. Not used See Spreading, function description, page 7:47.
3. Side shift (S815-P3)
The signal can be checked via the diagnostic menu. See section 8
4. Spreading in (S815-T1.2) Control system, group 8.4.9.3 ATTACH, menu 3.
5. Spreading out (S815-T1.1)
Side shift
6. Lock/open the twistlocks or lock tongues
(S815-T2) on full alignment Side shift left is activated when the potentiometer (position 3) is
7. Not used pushed in on the left-hand side. Side shift right is activated when the
right-hand side is pushed in. See Side shift, function description,
8. Pistol trigger (S815-T4): Changes the function
page 7:36.
of side shift to levelling (S815-P3)
9. Tilt out The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.1 ATTACH, menu 1.
10. Lift
11. Tilt in Levelling
12. Lower

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

potentiometer (position 3) is pressed in on the left-hand side, levelling
left is activated. Levelling right is activated when the right-hand side
is pushed in. See Active levelling, function description, page 7:76.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.1 ATTACH, menu 4.

Tilt
Tilt is controlled by moving the lever to the right (tilt out - position 10) or
the left (tilt in - position 12). See Tilt, function description, page 7:71.

The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.8.1 ELSERV, menu 1.

VDCF05.01GB Workshop Manual DCF 80-100

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

Open twistlocks or lock/open lock tongues

When the switch at position 6 is activated, the twistlocks open or the
lock tongues lock/open every other time if the conditions for such are
fulfilled.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.5 ATTACH, menu 5.

7.1.2 Switch, lock twistlock/lock tongue

Switch, lock twistlock/lock tongue, description

Switch (green) for locking twistlocks/lock tongues (S1003). The

switch is momentary in position 2.

Position 1 - Twistlocks/lock tongues are locked automatically when

009907 alignment with the load occurs. The parking brake must be OFF.

Position 0 - Twistlock locking not activated.

Position 2 - Twistlocks are locked manually. Button springs back.

Twistlocks are opened with the switch on the control lever, see Control
levers for electric servo, description, page 7:5.

The switch is supplied power by and sends a voltage signal to the

cab control unit (D790-1).

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.3 ATTACH, menu 5.

7.1.3 Switch, spreading 20\q-40\q

Switch, spreading 20'-40', description

Switch (green) for spreading between 20'-40' (S1012). Spreading

stops in the position it is in when the switch is released. The switch
is momentary.

This function is used to adapt the attachment to the width of the

containers.
009910

Position 0 - Spreading not activated.

Position 1 - Spreading out activated. Spreading's outer end position

is at 40'.

Position 2 - Spreading in activated. Spreading's inner end position

is at 20'.

The switch is supplied power by and sends a voltage signal to the

cab control unit (D790-1).

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.2 ATTACH, menu 3.

Workshop Manual DCF 80-100 VDCF05.01GB

7:8 7 Load handling – Switch, stop at 30\q

7.1.4 Switch, stop at 30\q

Switch, stop at 30', description

The switch (green) for spreading stop for the attachment at 30'
(S1004) activates the 30-foot stop. When the switch is depressed, the
35
function changes from spreading from 20'–40' to stop at 30'.
30-
The switch is supplied power by and sends a voltage signal to the
cab control unit (D790-1).

009909
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.2 ATTACH, menu 3.

7.1.13 Switch, automatic spreading

Switch automatic spreading, description

Switch (green) for automatic spreading between 20'-40' (S1004).

When the switch is pressed down spreading automatically goes to
the next position (20, 30 or 40 feet) if spreading is activated with the
control lever.

This switch is used to activate automatic spreading.

009908

Position 0 - Automatic spreading not activated.

Position 1 - Automatic spreading activated. Spreading is activated

with the switch for spreading 20'-40'.

The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1) when the switch is activated.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.4 ATTACH, menu 3.

WARNING
Risk of crushing and damage to the product!
Automatic spreading is stopped by activating
spreading in the opposite direction or deactivating the
function with the switch.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Lift and lower 7:9

7.2 Lift and lower

Lifting/lowering, function description
Condition Reference value Reference
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage
Twistlocks/lock Locked or unlocked, not Twistlocks, description, page 7:80 or Lifting hook, description,
tongues intermediate position page 7:93
Alignment Mast down: no contact Sensor, alignment, description, page 7:88 or Alignment and
detection sensor, description, page 7:102
Bypassed or lift height lower Section 8 Control system, group 8.2.6 Height limitation
Height limitation than height limitation

2,4 5
D790-1 D794
D1
D21 D15
D797-1
3,16,22
°<
21
1b 1a
D16 6 6
D3
7
LS
15
17 P

A2
13 B2
14 P PS
8,20,23
12
C
P EF
9
LS
11

19 C C

009367

18 10

Workshop Manual DCF 80-100 VDCF05.01GB

7:10 7 Load handling – Lift and lower

Pos Explanation Signal description Reference

1a The lifting/lowering control lever U = 0.5-4.5 V Control levers for electric servo,
(R8071-P1) sends the cab control unit description, page 7:5
Lower: U = <2.5 V
(D790-1) a voltage signal proportional
D1: Diagnostic menu, see section
to lever movement. Lift: U = 2.5 V
8 Control system, group 8.4.8.1
0.5 V is the fastest lowering ELSERV, menu 1
speed and 4.5 V is the fastest lift
speed. Lower voltage than 0.5
V and higher voltage than 4.5 V
is used to detect faults in cable
harnesses and controls.
1b The control lever (S815-P1) sends the US815-P1 = 0.5-4.5 V Lower: Control lever, description, page 7:6
cab control unit (D790-1) a voltage US815-P1 = <2.5 V
D1: Diagnostic menu, see section
signal proportional to lever movement.
Lift: US815-P1 = >2.5 V 8 Control system, group 8.4.8.1
ELSERV, menu 1
0.5 V is the fastest lowering
speed and 4.5 V is the fastest lift
speed. Lower voltage than 0.5
V and higher voltage than 4.5 V
is used to detect faults in cable
harnesses and controls.
2 The cab control unit (D790-1) sends the Checked by control system, error Section 11 Common electrics, group
frame control unit (D797-1) a lift/lower shown with error code. 11.5.3.1 Cab control unit (D790-1)
request via the CAN bus.
3 The frame control unit (D797-1) I = 380–650 mA Section 11 Common electrics, group
sends current proportional to the lever 11.5.3.2 Frame control unit (D797-1)
movement to the lift mast solenoid valve
D3: Diagnostic menu, see section
(Y6005) or the lower mast solenoid valve
8 Control system, group 8.4.8.3
(Y6004).
ELSERV, menu 3 and 8.4.8.4
ELSERV, menu 4
4 Control unit, cab (D790-1) transmits a Checked by control system, error Section 11 Common electrics, group
request for increased engine speed on shown with error code. 11.5.3.1 Cab control unit (D790-1)
the CAN bus.
5 Control unit, engine (D794) increases Checked by control system, error Section 11 Common electrics, group
the engine speed. shown with error code. 11.5.3.10 Engine control unit (D794)
6 The lift solenoid valve (Y6005) or - Control valve, lift and tilt, description,
the lower solenoid valve (Y6004) page 7:14
pressurises the control valve's lift spool
with servo pressure.
7 The control valve's lift spool changes - Control valve, lift and tilt, description,
position and pressurises the lift cylinders page 7:14
and sends a load signal to the hydraulic
oil pumps.
8 The lift cylinders are pressurised and the - Lift cylinder, description, page 7:16
mast is lifted or lowered.
9 The steering shuttle valve sends the - Section 10 Common hydraulics,
load signal on to the steering hydraulic group 10.5.3 Shuttle valve
pump and load handling.
10 The steering hydraulic oil pump and load See the pressure plate on the Section 10 Common hydraulics,
handling pump oil from the hydraulic oil left-hand frame beam. group 10.4.2 Axial piston pump with
tank to the priority valve and pressure variable displacement
reducer.
11 The priority valve leads feed pressure to - Section 5 Steering, group 5.2.2
Control valve, lifting/lowering. Priority valve
12 The pressure reducer reduces the oil See the pressure plate on the Pressure reducer, description, page
pressure from the steering hydraulic left-hand frame beam. 7:12
pump and load handling to servo
pressure for the control valve.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Hydraulic oil pump 7:11

Pos Explanation Signal description Reference

13 The accumulator stores servo pressure. See the pressure plate on the Accumulator servo circuit,
The non-return valve in the pressure left-hand frame beam. description, page 7:13
reducer makes it possible to store the
pressure when the engine is switched
off.
14 The servo filter cleans the servo oil - Servo filter, description, page 7:12
before Control valve lift and lower.
15 Quick-lift UB768-L1/1 = 5 V Sensor hydraulic pressure lift
cylinder, description, page 7:16
The hydraulic pressure sensor, left lift UB768-L1/2 = 0 V
cylinder (B768-L1) sends the frame D15: Diagnostic menu, see section
UB768-L1/5 = 0.5-4.5 V
control unit (D797-1) a voltage signal 8 Control system, group 8.4.5.6
proportional to oil pressure. HYD, menu 3 or group 8.4.10.1 OLS,
menu 1.
16 The frame control unit (D797-1) supplies U = 24 V Section 11 Common electrics, group
voltage to the quick-lift solenoid valve 11.5.3.2 Frame control unit (D797-1)
(Y6062) if the conditions for quick-lift are
D16: Diagnostic menu, see section 8
fulfilled.
Control system, group 8.4.5.6 HYD,
Conditions for quick-lift when lifting menu 6.
• Pressure in lift cylinders
• Transmission in neutral position
• Engine speed over 1200 rpm
• Damping inactive
17 The quick-lift solenoid valve (Y6062) - Valve block quick-lift, description,
conducts a load signal to the hydraulic page 7:35
oil pump for quick-lift.
18 The quick-lift hydraulic oil pump See the pressure plate on the Section 10 Common hydraulics,
pumps oil from the hydraulic oil tank to left-hand frame beam. group 10.4.2 Axial piston pump with
lifting/lowering control valve. variable displacement
19 The pressure limiting valve prevents - Section 10 Common hydraulics,
the pressure from becoming too high to group 10.2.4 Pressure limiting valve
Control valve lift and lower.
20 Lift speed increases. - Lift cylinder, description, page 7:16
21 Damping UB771/1 = 5 V Mast position sensor, description,
page 7:27
When the mast is approx. 50 cm from its UB771/2 = 0 V
topmost position, damping is activated. Section 11 Common electrics, group
UB771/3 = 0.5-4.5 V
11.5.3.3 Frame control unit (D797-1)
The mast position sensor (B7211-2)
sends the frame control unit (D797-1) D21: Diagnostic menu, see section
a voltage signal proportional to the lift 8 Control system, group 8.4.8.15
height. The control unit then transmits a ELSERV, menu 15.
damping request on the CAN bus.
22 The frame control unit (D797-1) - Section 11 Common electrics, group
deactivates quick-lift and reduces the 11.5.3.2 Frame control unit (D797-1)
control current to the lift solenoid valve
D3: Diagnostic menu, see section 8
(Y6005) or the lower solenoid valve
Control system, group 8.4.5.6 HYD,
(Y6004).
menu 6
23 Lift speed decreases. - Lift cylinder, description, page 7:16

Hydraulic diagram, see section E Schematics 10 Common hydraulics,

Hydraulic diagram DCF 80-100, electric servo

7.2.1 Hydraulic oil pump

Hydraulic oil pump, general
See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.

Workshop Manual DCF 80-100 VDCF05.01GB

7:12 7 Load handling – Servo filter

7.2.2 Servo filter

Servo filter, description
The servo filter protects the control valve's servo circuits against
impurities. The servo filter is located on the hydraulic plate in front of
the transmission, to the right of the accumulator for servo pressure.

The servo filter is a low-pressure filter with detachable filter insert. The
oil is cleaned when it passes through the filter insert's filter material.

The filter insert is pressed against the upper section of the filter
housing by a spring. Rubber gaskets seal between the insert and
filter housing. If the back pressure through the filter is too great then
the insert is pressed down so that the oil passes by the insert. This

009161
occurs if the oil is viscous (cold or incorrect viscosity) or if the filter
insert is clogged.

7.2.3 Pressure reducer

Pressure reducer, description
The pressure reducer reduces the pressure from the hydraulic oil
1
pump, which feeds servo pressure to the servo circuit for the control
2 valve. The pressure reducer is located on the hydraulic plate in front
of the transmission, fully assembled with the accumulator for the
3 servo pressure.

The servo pressure is stored in an accumulator for faster startup and

to emergency lower the load. A built-in non-return valve prevents
pressure leakage from the accumulator when the machine is not in
use.
7
6
5
4
009911

1. Accumulator servo pressure

2. Pressure reducer
3. Measurement connection
4. Pressure feed from servo filter
5. Return to tank
6. Servo pressure to control valve
7. Adjusting screw servo pressure

Servo pressure, inspection and adjustment

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

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Accumulator servo circuit 7:13

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

operating temperature, at least 50 ºC. As an alternative, operate
until the cooling fan is activated.
2 Machine in service position, see section B Safety.
3 Depressurise the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0–25 MPa) to the test outlet on the
pressure reducer.

009912
5 Start the engine and check the servo pressure. Compare with
the pressure plate.
M Pa Turn the steering wheel or activate a load handling function to
activate the hydraulic oil pumps. The servo pressure is higher
than the standby pressure of the hydraulic oil pumps.
6 If the pressure does not match the value specified on the pressure
plate, adjust the servo pressure adjusting screw until the right
pressure is obtained; see Pressure reducer, description, page
7:12. Loosen the lock nut and turn the adjusting screw.

NOTE
If the servo pressure is too high, a load handling function
must be activated so that servo pressure is used from the
accumulator for a reduction on the adjusting screw to be seen
on the pressure gauge. Sometimes the engine has to be shut
off between the checks.
009913

Clockwise: reduce pressure.

Anticlockwise: increase pressure.
7 Depressurise the hydraulic systems, See section B Safety.
8 Remove the pressure gauge and fit the protective cap on the
measuring outlet.

7.2.4 Accumulator servo circuit

Accumulator servo circuit, description
The accumulator stores pressurised oil and ensures that there is
servo pressure for activating control valve functions. The accumulator
is located on the hydraulic plate in front of the transmission, on top
of the pressure reducer.

The accumulator is a diaphragm type and is divided into two spaces

by a diaphragm. One side of the diaphragm is pressurised by
nitrogen gas. The other side is pressurised by the hydraulic oil, which
compresses the nitrogen gas.

Furthest up on the accumulator is a test outlet for checking gas

pressure and filling gas.
009914

Accumulator servo circuit

Workshop Manual DCF 80-100 VDCF05.01GB

7:14 7 Load handling – Control valve, lift and tilt

Accumulator servo circuit, replacement

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

1 Depressurise the hydraulic systems, See section B Safety.

2 Machine in service position, see section B Safety.

3 Detach the accumulator from its mounting.

4 Replace the accumulator.

5 Fit in the reverse order.

6 Check the oil level and fill with hydraulic oil as necessary.

7.2.5 Control valve, lift and tilt

Control valve, lift and tilt, description

4 7
3
8

2
5

1 6

14 11
13 12 10

009915

1. Solenoid valve, lift (Y6005) 8. Connection, rod side, right lift cylinder (B1)
2. Solenoid valve, lower (Y6004) 9. Connection, piston side, tilt cylinder (A1)
3. Connection, piston side, left lift cylinder (A2) 10. Connection, rod side, tilt cylinder (B1)
4. Connection, rod side, left lift cylinder (B2) 11. Connection return to tank (T)
5. Connection, feed from hydraulic oil pump (P) 12. Connection, piston side, tilt cylinder (A1)
6. Connection, feed from priority valve (P) 13. Solenoid valve, tilt out (Y6010)
7. Connection, piston side, right lift cylinder (A1) 14. Solenoid valve, tilt in (Y6011)

VDCF05.01GB Workshop Manual DCF 80-100

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

The control valve controls the speed and direction of lift and tilt. The
control valve is fitted on the hydraulic plate in front of the transmission.

The valve has two sections, one for the lift function and one for the
tilt function. The sections have many similarities, but are described
separately under the respective function. For tilt, see Control valve, lift
and tilt, description, page 7:73. Electric solenoid valves control the
flow from the valve.

The control valve is proportionally controlled by solenoid valves. This

means that both volume and direction of the flow from the valve can be
adjusted and that the valve also sends a control signal to the variable
pumps.

Electrically controlled pressure reducing valves (solenoid valves)

convert electric current into a low hydraulic pressure that is proportional
to the current, so-called servo pressure. The servo pressure acts on
the spring-centred control slide in the control valve for the function in
question and thereby controls the main flow.

The speed of the function is controlled by means of the flow being

regulated in proportion to the lever movement.
Lift slide
The lift slide controls the direction and flow of the oil to the lift cylinder.
Lift solenoid valve
The valve is controlled electrically with the Solenoid valve, lift (Y6005),
which is activated by the frame control unit, (D797-1). The servo valve
directs servo pressure to the lift slide which is proportional to the
control current to the solenoid valve.

The signals can be checked from the diagnostic menu, see section 8
Control system, group 8.4.8.3 ELSERV, menu 3.
Lower solenoid valve
The valve is controlled electrically with the Solenoid valve, lower
(Y6004), which is activated by the frame control unit, (D797-1). The
servo valve directs servo pressure to the lift slide which is proportional
to the control current to the solenoid valve.

The signals can be checked from the diagnostic menu, see section 8
Control system, group 8.4.8.4 ELSERV, menu 4.

Workshop Manual DCF 80-100 VDCF05.01GB

7:16 7 Load handling – Shuttle valve

7.2.6 Shuttle valve

Shuttle valve, description
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.

7.2.7 Lift cylinder

Lift cylinder, description
The lift cylinders lift and lower the inner mast which runs in the outer
mast. The lower part of the lift cylinders is fastened to the outer mast,
while its upper part is fastened to the inner mast, one on the right and
one on the left side of the mast.

A sensor that measures hydraulic pressure in the lift cylinder is

situated on the left lift cylinder.

The lift cylinder is fastened in the mast with nuts in the bottom and
a washer and screw in the top.

The lift cylinders are connected in parallel and fed from lift and tilt
control valve, see Control valve, lift and tilt, description, page 7:14.
009916

Hydraulic cylinders, repairs

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

7.2.8 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, description
The lift cylinder hydraulic pressure sensor (B768-L1) measures the
pressure in the lift cylinders and is located on the left lift cylinder.

Pressure is measured to determine whether quick-lift can be activated.

A sensor measures the pressure on the left-hand lift cylinder.

The sensor is supplied power by and sends a voltage signal

proportional to hydraulic oil pressure to the frame control unit
(D797-1).

The signal can be checked with the diagnostic menu, see section 8
Control system, group 8.4.5.3 HYD, menu 3 or group 8.4.10.1 OLS,
menu 1.
009917

Sensor, hydraulic pressure lift cylinder, piston side, left

(B768-L1)

Sensor, hydraulic pressure lift cylinder, replacement

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

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Sensor hydraulic pressure lift cylinder 7:17

3 Disconnect the cable harness from the sensor for hydraulic

pressure lift cylinder.
4 Remove the sensor for hydraulic pressure lift cylinder.

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

5 Fit the new sensor.

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

009188
6 Connect the cable harness to the sensor for hydraulic pressure.
Sensor hydraulic pressure lift cylinder 7 Clamp the cable harness as before.
8 Turn on the main electric power and start the engine.
9 Activate the lift carefully.

CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.

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

lifting/lowering works properly.

11 Check the oil level in the hydraulic tank with the attachment fully
lowered and mast tilted-in. The oil level should be at the top of the
sight glass. Top up if necessary.

CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic cylinders
fully retracted.

12 Check pressure and signals with the diagnostic menu; see section
8 Control system, group 8.4.5.3 HYD, menu 3 or group 8.4.10.1
OLS, menu 1.

Workshop Manual DCF 80-100 VDCF05.01GB

7:18 7 Load handling – Mast

7.2.9 Mast
Mast, description
The mast which has a clear view design lifts the load. The trolley runs
1 in the mast, which in turn holds the side lift attachment.

The lower part of the mast is fastened to the frame with two shafts
in both of the double lugs on the front of the frame. The mast is also
2 fastened in the frame with two tilt cylinders.

The mast consists of an outer mast and an inner mast manufactured

in high-strength steel with a minimum number of welds to provide
3 maximum strength. The inner mast runs in the outer mast and is lifted
and lowered with the lift cylinders. Between the inner and outer masts
are mast wheels and slide plates that guide the inner mast in the
outer mast and reduces the friction between the mast parts.

The lower part of the lifting cylinders is fastened to the outer mast,
4 while its upper part is fastened to the inner mast. When the oil is
pushed into the lift cylinders the cylinders' piston rods are pushed
out and the inner mast is lifted. The chain, which is attached to the
trolley (and in the outer frame), runs over chain wheels in the top of
the inner mast. In this way even the trolley is lifted at the same time
as the inner mast.

Hydraulic hoses and cables for the trolley and side lift attachment
functions run along the left side.
009918

1. Inner mast
2. Lifting eye
3. Outer mast
4. Lift cylinder

Mast, removing

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

NOTE
It is possible to remove the trolley and the side lift attachment as
a unit.

1 Remove the side lift attachment; see Side lift attachment,

removing, page 7:59.

2 Remove the trolley; see Trolley, removing, page 7:28.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Mast 7:19

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

009974
8 Mark up and disconnect the hydraulic connections of the lift
cylinders.

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

9 Mark up and detach the electrical connections of the mast.

009980

10 Mark up and release the hydraulic connections on the front plate

on the mast. Let the oil drain out.

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

11 Undo the electrical connectors for the mast.

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:20 7 Load handling – Mast

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

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

009984
14 Undo the nuts and bolts and remove the shafts which fix the mast
to the frame.
009979

15 Release the mast from the chassis.

WARNING
The mast can swing out when it is released from the
machine.
Risk of personal injury!
Stand in the mast!
009983

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Mast 7:21

16 Lift aside the mast.

009985

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:22 7 Load handling – Mast

Mast, installing

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

1 Turn off engine.

2 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.

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

4 Connect lifting equipment to the mast in a secure manner so the

mast does not tip when lifted.

009975

5 The shafts and bearing surfaces must be checked before the mast
is refitted for deep grooves/scratches, fibres must not protrude
above the bearing surface. If there are signs of damage, the
shaft/bearing must be replacement.

NOTE
The mast is attached to the machine's frame with strong shafts
which run in maintenance-free bearings.
It is extremely important that bearing surfaces are absolutely
clean when the mast is installed.
The shafts and bearings mentioned above must NEVER be
009977

lubricated with oil or grease.

Check that seals are intact and clean.

6 Lift the mast into place. It is important that the lifting equipment is
connected to the mast's lifting lugs in a secure manner.
009976

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Mast 7:23

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

009978
8 Fasten the shafts with bolts and lock nuts.
9 Start the engine and tilt the mast forwards as far as possible.
10 Turn off engine.
11 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
12 Turn the start key to position 0 and switch off the main power.
009979

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

14 Connect the tilt cylinders to the mast.

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:24 7 Load handling – Mast

15 Lubricate the connectors with contact grease and join them up.

16 Remove the plugs and connect the mast's hydraulic hoses on

the machine's front panel.
009981

17 Remove the plugs and connect the hydraulic hoses to the lift
cylinders.
18 Turn on the power supply and start the engine.
19 Check that the hydraulic connections are sealed tightly.
20 Check the mast functions.
21 Fit the trolley; see Trolley, installing, page 7:30.
22 Fit the side lift attachment; see Side lift attachment, installing,
page 7:62.
009980

Flanges on outer and inner mast beam

Flanges on outer and inner mast beam, description
The mast and its constituent parts are made of high-strength material
and are tested under extreme operating conditions and environments
to ensure a long and problem-free life.

Despite these efforts, problems can arise due to neglected

maintenance, improper handling, malfunction or damage to a mast
wheel, mast or trolley.

For example, lamination or pitting could occur on the mast beam

flange. This most often occurs on the inner mast, but could also occur
on the outer mast.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Mast 7:25

Flanges on outer and inner mast beam, repair

If the surface of the flanges has started to break down into small
flakes, this can be repaired so that the mast can still be used. This is
rectified by first grinding down the attacked surfaces and then "run-in"
the surface.

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

1 Machine in service position, see section B Safety.

2 Remove the trolley; see Trolley, removing, page 7:28.

3 Removing the mast, please refer to Mast, removing, page 7:18.

4 Separate the outer and inner mast.

5 Clean the mast components.

6 Grind the affected surfaces with a belt sander until the surface is
smooth and bright. Start with grit size 36-40 and finish with 60-80.
Grind in the longitudinal direction of the beam.
Check the internal measurement between the beam's front and
250 mm

rear flange. If the measurement exceeds 252 mm for a beam that

is supposed to be 250 mm, contact Cargotec.
7 Apply a thin layer of slide grease to the sliding surfaces of the
outer mast and reassemble the inner and outer masts.
010127C

8 Apply a thin layer of slide grease to the sliding surfaces of the

inner mast and fit the mast on the machine; see Mast, installing,
Mast beam size 250 mm. page 7:22.
9 Fit the trolley; see Trolley, installing, page 7:30.
10 Lift and lower the mast as follows to check its function.
Lift and lower the mast 20 times with 50% of the maximum load at
the right centre of gravity distance.
Lift and lower the mast 20 times with 75% of the maximum load at
the right centre of gravity distance.
Lift and lower the mast 20 times with the maximum load at the
right centre of gravity distance.
11 Check that contact surfaces look normal. If not, contact Cargotec.

Workshop Manual DCF 80-100 VDCF05.01GB

7:26 7 Load handling – Mast

Slide plates in inner mast, adjusting

NOTE
If the slide plate extends less than 3 mm from the holder, replace it.

1 Lubricate the inner sliding surfaces of the outer mast with a thin
layer of slide grease.

2 Lift the inner mast 200 mm.

3 Adjust the slide plate in the bottom part of the outer mast so that it
lies against or has no more than 0.5 mm play to the outer mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
4 Raise the mast to its end position and check that the slide plates
010152 do not pinch too hard against the sliding surface.

Slide plates in outer mast, adjusting

NOTE
If the slide plate extends less than 3 mm from the holder, replace it.

1 Lubricate the outer sliding surfaces of the inner mast with a thin
layer of slide grease.

2 Lower the inner mast to its bottom position.

3 Lift the inner mast 200 mm.

4 Adjust the slide plate in the top part of the outer mast so that it lies
against or has no more than 0.5 mm play to the inner mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
5 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010130

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Mast position sensor 7:27

Mast wheel, adjusting

1 Use a drift to tap out the spring pin (position 4) from the inside.
1
NOTE
Check that the cover washer is centred on the clamping screw.
2
3 2 Screw in the clamping screw (position 5) so that the wheel is
completely locked.

NOTE
4
Rotate the mast wheel while tightening the clamping screw.
5
3 Loosen the clamping screw until the wheel rotates, slightly slowly.
Turn the clamping screw so that the next hole for the tubular pin
fits.
6
7 NOTE
Check that there is clearance between the mast wheel and the
mast beam.

4 Lock the clamping screw with the spring pin.

010126

1. Impeller
2. Circlip
3. Cover washer
4. Spring pin
5. Clamping screw
6. Inner bearing
7. Outer bearing

7.2.10 Mast position sensor

Mast position sensor, description
Position sensor mast (B7211-2) activates damping when lifting. The
position sensor is used to deactivate the hydraulic oil pump for quick-lift
so that the lift speed decreases once the mast approaches its upper
limit.

For checking and adjusting, see Position sensor, adjusting, page 7:4.

The position sensor sends a signal to the frame control unit (D797-1).

The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.8.15 ELSERV, menu 15.

Workshop Manual DCF 80-100 VDCF05.01GB

7:28 7 Load handling – Trolley

7.2.11 Trolley
Trolley, description
The trolley holds, via hydraulic cylinders, the side lift attachment
and runs along the inner mast with slide plates and mast wheels.
The following functions are controlled via the trolley cylinders:
• Side shift - the attachment can be shifted to the side ± 600
mm.
• Mechanical levelling - the attachment can be levelled ± 3°.
• Active levelling - the attachment can be levelled ± 3°.
The trolley also houses the control valve for the hydraulic
functions of the trolley and side lift attachment.
See also Side shift cylinder, description, page 7:42 and Levelling
cylinder, description, page 7:79.

2
1 2
1
3

5 4
4 5

014791
013589

3 3
Trolley Trolley with levelling
1. Side shift cylinder 1. Side shift cylinder
2. Control valve, attachment 2. Control valve, attachment
3. Slide plates 3. Slide plates
4. Mast wheels 4. Mast wheels
5. Levelling cylinders

Trolley, removing

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

1 Remove the side lift attachment; see Side lift attachment,

removing, page 7:59.

2 Connect lifting equipment to the trolley in a secure manner.

3 Disconnect the main power supply.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Trolley 7:29

4 Disconnect the trolley cable by undoing the lock plate screws.

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

009995
5 Mark up and disconnect the carriage's hydraulic connections. Let
the oil run out.

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

6 Raise the carriage with the lifting equipment (overhead crane) to

slacken the chains.
009987

7 Undo the nuts and remove the chain tensioners.

8 Start the engine and tilt the mast rearwards.
9 Raise the mast enough for the carriage to release from the mast.
10 Lower the mast again.
11 Lift aside the trolley. Put it on blocks and supports to prevent
damage to the cylinders.
12 Undo the lifting equipment (travelling crane).
013591
009986

Trolley with levelling

Workshop Manual DCF 80-100 VDCF05.01GB

7:30 7 Load handling – Trolley

Trolley, installing

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

1 Park the machine with the mast vertical.

2 Raise the mast high enough to position the carriage in the inner
mast and lift it into place.

3 Run down the mast so the trolley fastens in the inner mast. Stop
the mast in a position where the chains can be attached to the
trolley. Fit the chain tensioners and adjust and fasten with the nuts.
4 Lower the carriage as far as possible.
5 Turn off engine.
6 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
7 Turn the start key to position 0 and switch off the main power.
013591
009986

Trolley with levelling

8 Remove the plugs and connect the mast's hydraulic hoses and
the carriage wiring.
009987

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Trolley 7:31

9 Connect the trolley cable.

Lubricate the connectors with contact grease and connect them
Fasten the wiring with the lock plate.
10 Fit the side lift attachment; see Side lift attachment, installing,
page 7:62.
11 Turn on the power supply and start the engine.
12 Check that the hydraulic connections are sealed tightly.
13 Check the trolley functions.

009995

Workshop Manual DCF 80-100 VDCF05.01GB

7:32 7 Load handling – Trolley

Slide plates in trolley, adjusting and, if necessary,

replacing
1 Remove the trolley; see Trolley, removing, page 7:28.

NOTE
Minor adjustment to the clearance between the trolley and inner
mast is possible without removing the trolley.

2 If the slide plate extends less than 3 mm from the holder, replace it.
A 3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.

B
013593

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

4 Use a sliding calliper to measure the external measurements

between the trolley slide plates.

D
013648

Measure the exterior measurements between the trolley

slide plates (C and D).

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Trolley 7:33

5 Adjust trolley clearance by removing the screws and adding or

removing shims.
a. If the width at A and B is the same:
2
Adjust C and D to be equal to or max. 0.5 mm more than A.
1 b. If A is greater than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm more than B.
c. If A is less than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm less than B.
6 Lubricate the inner sliding surfaces of the inner mast with a thin
layer of slide grease.

013648
1
2 7 Fit the trolley; see Trolley, installing, page 7:30.

1. Screws 8 Lift the trolley all the way up and check that the slide plates do not
clamp too hard against the sliding surfaces.
2. Shim

Slide plates in the trolley with levelling, adjusting and,

if necessary, replacing

1 Remove the trolley; see Trolley, removing, page 7:28.

NOTE
Minor adjustment to the clearance between the trolley and inner
mast is possible without removing the trolley.

A 2 If the slide plate extends less than 3 mm from the holder, replace it.
3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.

B
010123

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:34 7 Load handling – Trolley

4 Use a sliding calliper to measure the external measurements

between the trolley slide plates.

D
010124

Measure the exterior measurements between the trolley

slide plates (C and D).

5 Adjust trolley clearance by removing the screws and adding or

removing shims.
2 a. If the width at A and B is the same:
Adjust C and D to be equal to or max. 0.5 mm more than A.
1
b. If A is greater than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm more than B.
c. If A is less than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm less than B.
6 Lubricate the inner sliding surfaces of the inner mast with a thin
010125

1 layer of slide grease.

2
7 Fit the trolley; see Trolley, installing, page 7:30.
1. Screws
8 Lift the trolley all the way up and check that the slide plates do not
2. Shim clamp too hard against the sliding surfaces.

Mast wheel, adjusting

For mast wheel adjustment, see Mast wheel, adjusting, page 7:27.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Valve block quick-lift 7:35

7.2.12 Valve block quick-lift

Valve block quick-lift, description
Valve block quick-lift controls activation of the hydraulic oil pump for
quick-lift, see section 10 Common hydraulics, group 10.4.2 Axial
piston pump with variable displacement. When the Solenoid valve
enabling quick-lift (Y6062) is activated, the Valve block directs the
load signal to the hydraulic oil pump for quick-lift, which feeds extra
oil to the control valve lift and tilt. The valve block is fitted on the
hydraulic plate in front of the transmission.

The solenoid valve for quick-lift connection (Y6062) is supplied

voltage from the frame control unit (D797-1) upon activation.

009922
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.7 HYD, menu 7.
Valve block quick-lift

7.2.13 Pipes and hoses

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:36 7 Load handling – Side shift

7.4 Side shift

Side shift, function description
Condition Reference value Reference
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage

1b 1a D1

2
D790-1

D797-1 D791-1
3 8 D8
D3 11
9
C

P1 A

4
T1 B

10
5

C
6
7

014798
Pos Explanation Signal description Reference
1a The side shift control lever U = 0.5-4.5 V Control levers for electric servo, description,
(R8073-P3) sends the cab control unit page 7:5
Left: U = <2.5 V
(D790-1) a voltage signal proportional
D1: Diagnostic menu, see section 8 Control
to lever movement. Right: U = 2.5 V
system, group 8.4.9.1 ATTACH, menu 1
0.5 V is the highest left side
shift speed and 4.5 V is
the highest right side shift
speed. Lower voltage than
0.5 V and higher voltage
than 4.5 V is used to detect
faults in cable harnesses
and controls.
1b The control lever (S815-P3) sends US815-P3 = 0.5-4.5 V Control lever, description, page 7:6
the cab control unit (D790-1) a
Right: US815-P3 = <2.5 V D1: Diagnostic menu, see section 8 Control
voltage signal proportional to lever
system, group 8.4.9.1 ATTACH, menu 1
movement. Left: US815-P3 = >2.5 V
0.5 V is the highest right
side shift speed and 4.5 V
is the highest left side shift
speed. Lower voltage than
0.5 V and higher voltage
than 4.5 V is used to detect
faults in cable harnesses
and controls.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Hydraulic oil pump 7:37

Pos Explanation Signal description Reference

2 Control unit, cab (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
side shift left or right on the CAN bus. system, error shown Cab control unit (D790-1)
with error code.
3 The frame control unit (D797-1) U = 24 V Section 11 Common electrics, group 11.5.3.2
activates the solenoid valve for main Frame control unit (D797-1)
pump relief (Y6062-2).
D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 The solenoid valve for main pump - Valve block, main pump relief, description,
relief (Y6062-2) routes a relieved page 7:46
constant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
5 The attachment shuttle valve sends - Section 10 Common hydraulics, group 10.5.3
the load signal on to the hydraulic oil Shuttle valve
pump for load handling or the cab tilt
shuttle valve.
The cab tilt shuttle valve sends the - Section 10 Common hydraulics, group 10.5.3
6 load signal on to the hydraulic oil Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load See the pressure plate on Section 10 Common hydraulics, group 10.4.2
handling pumps oil from the hydraulic the left-hand frame beam. Axial piston pump with variable displacement
oil tank.
8 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group 11.5.3.5
activates the solenoid valve for side Attachment control unit (D791-1)
shift left (Y6020) or the solenoid valve
D8: Diagnostic menu, see section 8 Control
for side shift right (Y6021).
system, group 8.4.9.11 ATTACH, menu 11 and
group 8.4.9.12 ATTACH, menu 12
9 The solenoid valve for side shift left - Attachment control valve, description, page
(Y6020) or the solenoid valve for side 7:38
shift right (Y6021) pressurises the
side shift spool in the attachment
control valve.
10 The control valve's side shift slide - Attachment control valve, description, page
changes position and pressurises the 7:38
side shift cylinders.
11 The side shift cylinders push in the - Side shift cylinder, description, page 7:42
main beam sideways in relation to
the trolley.

Hydraulic diagram, see section E Schematics group 10 Common

hydraulics, Hydraulic diagram DCF 80-100, electric servo

7.4.1 Hydraulic oil pump

Hydraulic oil pump, general
See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.

Workshop Manual DCF 80-100 VDCF05.01GB

7:38 7 Load handling – Control valve, attachment

7.4.2 Control valve, attachment

Attachment control valve, description
1 2 3 6 9 12 16

014782
5 4 8 7 11 10 13 14 15 17
1. Connection return to tank (T) 10. Solenoid valve spreading out left (Y6018L)
2. Connection, feed from hydraulic oil pump (P) 11. Connection to spreading cylinder left
3. Solenoid valve, side shift right (Y6021) 12. Solenoid valve spreading in right (Y6019R)
4. Solenoid valve, side shift left (Y6020) 13. Solenoid valve spreading out right (Y6018R)
5. Connection to side shift cylinder 14. Connection to spreading cylinder right
6. Solenoid valve, lock twistlock (Y6040) 15. Solenoid valve, levelling right (Y6035)
7. Solenoid valve, open twistlock (Y6039)
16. Solenoid valve, levelling left (Y6036)
8. Connection to lock cylinders
17. Connection to levelling cylinders
9. Solenoid valve spreading in left (Y6019L)
Control valve attachment controls the hydraulic functions on the
attachment. The control valve is located up on the trolley. Electric
solenoid valves control the flow from the valve.
The control valve is an electro-hydraulically controlled, proportional and
pressure-compensated directional control valve. Electrically controlled
solenoid valves convert current to servo pressure. The servo pressure
controls the spring-centred valve slides, which control pressure and
flow for the function in question. The valve slides have a flow limit so
that several functions can be used simultaneously. This enables them
to control the main flow.
The control valve has built-in supply of pilot pressure. This means that
the valve has built-in pressure reduction which converts feed pressure
to servo pressure for the various functions. Supply of pilot pressure is
common for all functions. This reduces pressure variations due to long
hoses and reduces the number of hoses to the valve.
The control valve has the following sections:
• Levelling
• Spreading right extension beam
• Spreading left extension beam
• Twistlocks/lock tongues
• Side shift
Side shift slide
The valve slide controls the direction and speed of side shift.
The valve spool is controlled by a solenoid valve for side shift right and
a solenoid valve for side shift left.
Solenoid valve, side shift left
The solenoid valve for side shift left controls pressure to the side shift
spool so that the side shift spool opens and pressurises the side shift
cylinder.

VDCF05.01GB Workshop Manual DCF 80-100

7 Load handling – Control valve, attachment 7:39

Solenoid valve, side shift left is controlled electrically by Solenoid valve,

side shift left (Y6020), which is activated by Control unit, attachment
(D791-1). The solenoid valve directs servo pressure to the side shift
slide in proportion to the control current to the solenoid valve.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.11 ATTACH, menu 11.
Solenoid valve, side shift right
The solenoid valve for side shift right controls pressure to the side
shift spool so that the side shift spool opens and pressurises the side
shift cylinder.

Solenoid valve, side shift is controlled electrically by Solenoid valve,

side shift right (Y6021), which is activated by Control unit, attachment
(D791-1). The solenoid valve directs servo pressure to the side shift
slide in proportion to the control current to the solenoid valve.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.12 ATTACH, menu 12.

Control valve attachment, replacement

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

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

3 Remove the attaching bolts and lift away the plate fitted over the
control valve.
4 Mark and disconnect the hydraulic hoses from the control valve.

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

5 Mark and disconnect the cable harness from the control valve.
013595

Workshop Manual DCF 80-100 VDCF05.01GB

7:40 7 Load handling – Control valve, attachment

6 Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
7 Transfer the connection adapters to the new control valve.

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

NOTE
Transfer one connection at a time so that the marking is not

013596
mixed up.

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

9 Lift the valve into place and fit the attaching bolts.
10 Connect the cable harness to the control valve according to the
marking.
11 Connect the hydraulic hoses to the control valve in according to
the marking.

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

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

13 Check that the valve\qs hydraulic connections are sealed.
14 Check that the attachment is working.

CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.

15 Check the oil level in hydraulic oil tank with all hydraulic cylinders
in the retracted position. The oil level should be at the top of the
sight glass. Top up if necessary.

CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic cylinders
fully retracted.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Control valve, attachment 7:41

Control valve attachment, checking hydraulic

pressure

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

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

operating temperature, at least 50 ºC. As an alternative, operate
until the cooling fan is activated.

˚C 2 Turn off engine.

3 Machine in service position, see section B Safety.

˚C

000475
Operating menu, hydraulic oil temperature

4 Connect a pressure gauge to the measuring outlet B2 on the

hydraulic oil pump for lift, tilt and attachment.
5 Start the engine and run it at idle. Check the pressures in the
attachment's different functions by letting each function go to its
end-position and then reading off the pressure gauge.
The pressures should be:

Function Pressure
Side shift 13.0 MPa
Spreading right extension 13.0 MPa
beam
Spreading left extension beam 13.0 MPa
20.0 MPa
Levelling
013597

Twistlocks/lock tongues Same as feed pressure.

Measuring outlet on hydraulic oil pump for lift, tilt and 6 Remove the pressure gauge and fit the protective cap on the
attachment. measuring outlet.

Workshop Manual DCF 80-100 VDCF05.01GB

7:42 7 Load handling – Side shift cylinder

7.4.3 Side shift cylinder

Side shift cylinder, description
The side shift cylinder sits between the trolley and the side lift
attachment. It shifts the main beam laterally in relation to the
trolley.

009923
013598

Side shift cylinder Side shift cylinder, on the trolley with levelling

Hydraulic cylinders, repairs

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

7.4.4 Shuttle valve

Shuttle valve, description
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Trolley 7:43

7.4.5 Trolley
Trolley, description
See Trolley, description, page 7:28.

Slide plates between trolley and attachment,

adjustment/replacement

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

and spreading run all the way in.

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

3 Clean and measure the thickness of the lower slide plates.

1 NOTE
The thickness of the slide plate should be at least 10 mm.

4 Replace the lower slide plates, if necessary, by loosening the

attachment's mounting.
5 Unload the tension from the slide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the side lift attachment or inserting wedges to alter
the position of the side lift attachment in the trolley.
6 Remove the slide plate and fit a new one. Repeat with the other
lower slide plates (x4).
7 Reassemble the attachment's mounting.

3
2
013681

3
The illustration shows the slide plates between the
attachment and trolley.
1. Upper slide plates
2. Lower slide plates
3. Attachment's fastening

Workshop Manual DCF 80-100 VDCF05.01GB

7:44 7 Load handling – Trolley

8 Clean and measure the thickness of the upper slide plates.

1 2 3
The upper slide plates can be replaced and adjusted using shims
when the attachment is in position in the trolley.

NOTE
The thickness of the slide plate should be at least 10 mm.

9 Remove the counterhold.

10 Loosen the slide plate's attaching bolt slightly so that the slide
4 plate releases from the carriage.
11 Insert the required number of shims to remove the play between
attachment and carriage. Alternatively replace the slide plate.
12 Refit the counterhold and tighten the attaching bolt that secures
the slide plate.
13 Check the play between side lift attachment and the trolley. The
013682

play should be less than 1 mm with all slide plates fitted.

Use more shims to adjust any play.
The illustration shows the slide plates between the
trolley and attachment.
1. Upper slide plates
NOTE
Do not use too thick shims. Too little play increases wear on
2. Shim
the slide plates.
3. Counterhold
4. Screw
NOTE
Check that the attaching bolts for all slide plates are tightened.

14 Check that the sliding surface is clean and lubricate the sliding
surface on the side lift attachment.
15 Start the machine and side shift the attachment to its end positions.
Check that the play between the trolley and the attachment is
sufficient along the whole attachment and that no metallic contact
occurs. Adjust as necessary, using the shims.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Trolley 7:45

Slide plates in the trolley with mechanical

levelling, adjusting/replacing

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

and spreading run all the way in.

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

3 Unload the tension from the slide plate in question.

The pressure can be relieved from the slide plates by raising the
outer edge of the side lifting attachment or inserting wedges to
alter the position of the side lifting attachment in the lifting beam.
4 Remove the attaching bolts for the slide plate's bracket.
5 Remove the slide plate's guide screw.
6 Pull out the slide plate with spacer plate and bracket.
7 Measure the thickness of the slide plate. Replace if necessary.

1 NOTE
The thickness of the slide plate should be at least 10 mm.

8 Place the slide plate in the correct position.

Check the play between side lift attachment and the trolley. The
play should be less than 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.

NOTE
In general, the upper slide plates on the front of the lifting
carriage and the lower slide plates on the rear of the carriage
are adjusted with shim plates.

1 NOTE
Do not use too thick shims. Too little play increases wear on
2 the slide plates.

NOTE
Check that the attaching bolts for all slide plates are tightened.
009190

9 Fit the slide plate bracket.

The illustration shows slide, roller plates on the trolley 10 Fit the slide plate steering screw.
with a mechanical levelling.
11 Check that the sliding surface is clean and lubricate the sliding
1. Slide and roller plates
surface on the side lift attachment.
2. Fastening and guide screws for slide and roller
plates 12 Start the machine and check the side lift attachment's functioning.
Try to lift a container and then check the side lift attachment's play
again on the trolley.

Workshop Manual DCF 80-100 VDCF05.01GB

7:46 7 Load handling – Valve block, main pump relief

7.4.6 Valve block, main pump relief

Valve block, main pump relief, description
Valve block, main pump relief is an electrically controlled valve. It
leads a relieved constant pressure as a load signal to the hydraulic oil
pump for load handling when attachment functions are activated. The
valve block is fitted on the hydraulic plate in the engine compartment
in front of the transmission.

When the solenoid valve is activated the pressure is controlled from

hydraulic's feed through a shuttle valve to the hydraulic oil pump
for load handling. A restriction before the valve block ensures that
pressure for control of the hydraulic oil pump's does not become too
high. When the solenoid valve is not activated, the load signal is

009955
drained to the tank and the inlet from the Control valve's supply is
closed.
Valve block, main pump relief
The valve is regulated electrically by the solenoid valve for main pump
relief (Y6062-2), which is activated by the frame control unit (D797-1).

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.6 HYD, menu 6.

7.4.7 Relief valve, attachment

Relief valve attachment, description
Relief valve attachment opens a connection between the attachment's
pressure feed and tank. This is used to drain the pressure in the
hoses for the attachment before working on the hydraulic system.
The relief valve is located by the hydraulic oil pump for load handling
on the spacer block.
009961

The illustration depicts an open valve

7.4.8 Pipes and hoses

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

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Spreading (positioning) 7:47

7.5 Spreading (positioning)

Spreading, function description
Condition Reference value Reference
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description, page 7:80 or Lifting hook, description, page
activated 7:93
Section 8 Control system, group 8.2.2 Bypass

D1
1b
1a
2
D790-1

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

3
D8 D9

D3 10,19 11,20
C
P1 12
4 21
T1
A B A B
D15 D16

5 15 16

C
6 13,22 14,22
7

014799
Pos Explanation Signal description Reference
1a The switch for spreading 20'-40' U = 24 V Switch, spreading 20'-40', description, page 7:7
(S1012) sends a voltage signal to
D1: Diagnostic menu, see section 8 Control
the cab control unit (D790-1).
system, group 8.4.9.3 ATTACH, menu 3
1b The control lever (S815-T1.1 and Spreading: US815-T4 = 24 V Control lever, description, page 7:6
S815-T1.2) sends a voltage signal
Out: US815-T1.2 = 24 V D1: Diagnostic menu, see section 8 Control
to the cab control unit (D790-1).
system, group 8.4.9.2 ATTACH, menu 3
In: US815-T1.1 = 24V
2 The cab control unit (D790-1) Checked by control Section 11 Common electrics, group 11.5.3.1
transmits spreading in or out on the system, error shown Cab control unit (D790-1)
CAN bus. with error code.
3 The frame control unit (D797-1) U = 24 V Section 11 Common electrics, group 11.5.3.3
activates the solenoid valve for main Frame control unit
pump relief (Y6062-2).
D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 The solenoid valve for main pump - Valve block, main pump relief, description,
relief (Y6062-2) routes a relieved page 7:46
constant pressure to the hydraulic
oil pump for load handling. This
serves as a load signal.

Workshop Manual DCF 80-100 VDCF05.01GB

7:48 7 Load handling – Spreading (positioning)

Pos Explanation Signal description Reference

5 The attachment shuttle valve sends - Section 10 Common hydraulics, group 10.5.3
the load signal on to the hydraulic oil Shuttle valve
pump for load handling or the cab
tilt shuttle valve.
The cab tilt shuttle valve sends the - Section 10 Common hydraulics, group 10.5.3
6 load signal on to the hydraulic oil Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load See the pressure plate on Section 10 Common hydraulics, group 10.4.2
handling pumps oil from the the left-hand frame beam. Axial piston pump with variable displacement
hydraulic oil tank to the attachment
control valve.
8 The attachment control unit I = 350–600 mA Section 11 Common electrics, group 11.5.3.5
(D791-1) activates the solenoid Attachment control unit (D791-1)
valve for spreading out left (Y6018L)
D8: Diagnostic menu, see section 8 Control
or the solenoid valve for spreading
system, group 8.4.9.17 ATTACH, menu 17 and
in left (Y6019L).
8.4.9.18 ATTACH, menu 18
9 The attachment control unit I = 350–600 mA Section 11 Common electrics, group 11.5.3.5
(D791-1) activates the solenoid Attachment control unit (D791-1)
valve for spreading out right
D9: Diagnostic menu, see section 8 Control
(Y6018R) or the solenoid valve for
system, group 8.4.9.19 ATTACH, menu 19 and
spreading in right (Y6019R).
8.4.9.20 ATTACH, menu 20
10 The solenoid valve for spreading - Attachment control valve, description, page
out left (Y6018L) or the solenoid 7:38
valve for spreading in left (Y6019L)
pressurises the left spreader spool
in the attachment's control valve.
11 The solenoid valve for spreading - Attachment control valve, description, page
out right (Y6018T) or the solenoid 7:38
valve for spreading in right (Y6019T)
pressurises the right spreader spool
in the attachment's control valve.
12 The control valve's spreader spools - Attachment control valve, description, page
change position and direct pressure 7:38
to the spreader cylinders.
13 Left spreader cylinder pushes left - Spreading cylinder, description, page 7:54
spreader beam in or out in the
attachment.
14 Right spreader cylinder pushes - Spreading cylinder, description, page 7:54
right spreader beam in or out in the
attachment.
15 The sensor for end position 20'-40' Sensor directly opposite Position sensor spreading, description, page
left (B769L) sends a voltage signal indicator plate: U > 24 V 7:69
to the attachment control unit
D15: Diagnostic menu, see section 8 Control
(D791-1).
system, group 8.4.9.6 ATTACH, menu 6
16 The sensor for end position 20'-40' Sensor directly opposite Position sensor spreading, description, page
right (B769R) sends a voltage indicator plate: U = 24 V 7:69
signal to the attachment control unit
D16: Diagnostic menu, see section 8 Control
(D791-1).
system, group 8.4.9.6 ATTACH, menu 6
17 The attachment control unit (D791-1) - Section 11 Common electrics, group 11.5.3.5
reduces the control current to the Attachment control unit (D791-1)
solenoid valve for spreading out left
D8: Diagnostic menu, see section 8 Control
(Y6018L) or the solenoid valve for
system, group 8.4.9.17 ATTACH, menu 17 and
spreading in left (Y6019L).
8.4.9.18 ATTACH, menu 18
18 The attachment control unit (D791-1) - Section 11 Common electrics, group 11.5.3.5
reduces the control current to the Attachment control unit (D791-1)
solenoid valve for spreading out
D9: Diagnostic menu, see section 8 Control
right (Y6018R) or the solenoid valve
system, group 8.4.9.19 ATTACH, menu 19 and
for spreading in right (Y6019R).
8.4.9.20 ATTACH, menu 20

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Spreading (positioning) 7:49

Pos Explanation Signal description Reference

19 The solenoid valve for spreading - Control valve attachment, replacement, page
out left (Y6018L) or the solenoid 7:39
valve for spreading in left (Y6019L)
D8: Diagnostic menu, see section 8 Control
reduces the pressure to the left
system, group 8.4.9.17 ATTACH, menu 17 and
spreader spool in the attachment's
8.4.9.18 ATTACH, menu 18
control valve.
20 The solenoid valve for spreading out - Control valve attachment, replacement, page
right (Y6018R) or the solenoid valve 7:39
for spreading in right (Y6019R)
D9: Diagnostic menu, see section 8 Control
reduces the pressure to the right
system, group 8.4.9.19 ATTACH, menu 19 and
spreader spool in the attachment's
8.4.9.20 ATTACH, menu 20
control valve.
21 The control valve's spreader spools - Attachment control valve, description, page
change position and reduce the 7:38
pressure to the spreader cylinders.
22 Spreader speed decreases. - Position sensor spreading, description, page
7:69

Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics, Hydraulic diagram DCF 80-100, electric servo.

Workshop Manual DCF 80-100 VDCF05.01GB

7:50 7 Load handling – Spreading (positioning)

30-foot stop, function description

Condition Reference value Reference

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks/Lock tongues Unlocked or Twistlocks, description, page 7:80 or Lifting hook, description, page 7:93
bypass activated
Section 8 Control system, group 8.2.2 Bypass

D1 D2
2b 2a 1
35
30-

3
D790-1

D791-1
4,7,9,11 D5

D8 30' 30'

014803
4,7 4,7 5 6 8 10

Pos Explanation Signal description Reference

1 The switch for stop at 30' (S1004) sends Switch in on position: Switch, stop at 30', description, page 7:8
a voltage signal to the cab control unit
Conn. 1: U = 0 V D1: Diagnostic menu, see section 8 Control
(D790-1).
system, group 8.4.9.2 ATTACH, menu 3
Conn. 5: U = 24 V
Switch in off position:
Conn. 1: U = 24 V
Conn. 5: U = 24 V
2a The switch for spreading 20'-40' U = 24 V DC Switch, spreading 20'-40', description, page
(S1012) sends a voltage signal to the 7:7
cab control unit (D790-1).
D2: Diagnostic menu, see section 8 Control
system, group 8.4.9.3 ATTACH, menu 3
2b The control lever (S815-T1.2) sends a Spreading: US815-T4 = 24 V Control lever, description, page 7:6
voltage signal to the Cab control unit
Out: US815-T1.2 = 24 V D2: Diagnostic menu, see section 8 Control
(D790-1).
system, group 8.4.9.2 ATTACH, menu 2
In: US815-T1.1 = 24V
3 Control unit, cab (D790-1) sends Checked by control Section 11 Common electrics, group
spreading 30' on the CAN bus. system, error shown 11.5.3.1 Cab control unit (D790-1)
with error code.
4 Spreading is activated in the same way - Spreading, function description, page 7:47
as the normal spreading steps 3–14.
5 When the left spreader beam Sensor directly opposite Position sensor spreading, description, page
approaches the 30' mark, the sensor indicator plate: U = 24 V 7:69
for 30' end position left (B777L) sends a
D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control
system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Spreading (positioning) 7:51

Pos Explanation Signal description Reference

6 When the right spreader beam Sensor directly opposite Position sensor spreading, description, page
approaches the 30' mark, the sensor for indicator plate: U = 24 V 7:69
30' end position left (B777R) sends a
D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control
system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
7 The attachment control unit (D791-1) - Spreading, function description, page 7:47
dampens the speed in the same way as
in normal spreading, steps 17–22.
8 When the left spreader beam is at the Sensor directly opposite Position sensor spreading, description, page
30' mark, the sensor for 20'-40' end indicator plate: U = 24 V 7:69
position (B769L) sends a voltage signal
D8: Diagnostic menu, see section 8 Control
to the attachment control unit (D791-1).
system, group 8.4.9.5 ATTACH, menu 5
9 The attachment control unit (D791-1) U=0V Attachment control valve, description, page
cuts off the current to the solenoid 7:38
valve for spreading out left (Y6018L) or
the solenoid valve for spreading in left
(Y6019L).
10 When the right spreader beam is at the Sensor directly opposite Position sensor spreading, description, page
30' mark, the sensor for 20'-40' end indicator plate: U = 24 V 7:69
position (B769R) sends a voltage signal
D8: Diagnostic menu, see section 8 Control
to the attachment control unit (D791-1).
system, group 8.4.9.5 ATTACH, menu 5
11 The attachment control unit (D791-1) U=0V Attachment control valve, description, page
cuts off the current to the solenoid valve 7:38
for spreading out right (Y6018R) or the
solenoid valve for spreading in right
(Y6019R).

Hydraulic diagram, see section E Schematics group 10 Common

hydraulics, Hydraulic diagram DCF 80-100, electric servo

Workshop Manual DCF 80-100 VDCF05.01GB

7:52 7 Load handling – Spreading (positioning)

Automatic spreading 20-40 foot, function

description

Condition Reference value Reference

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description, page 7:80 or Lifting hook, description, page
activated 7:93
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system

2
D1 D2
1b 1a

3 7
D790-1 D795

D791-1 D9
D10 D8 D11 4, 5, 8 9 D13 D12

10 8 11 6 13 9 12

009347
D5

Pos Explanation Signal description Reference

1a. The switch for spreading 20'-40' U = 24 V Switch, spreading 20'-40', description, page 7:7
(S1012) sends a voltage signal to
D2: Diagnostic menu, see section 8 Control
the cab control unit (D790-1).
system, group 8.4.9.3 ATTACH, menu 3
1b The control lever (S815-T1.1 and Spreading: US815/T4 = 24 V Control lever, description, page 7:6
S815-T1.2) sends a voltage signal to
Out: US815/T1.2 = 24 V D1: Diagnostic menu, see section 8 Control
the cab control unit (D790-1).
system, group 8.4.9.2 ATTACH, menu 2
In: US815/T1.1 = 24 V
2 The switch for automatic spreading Switch in on position: Switch automatic spreading, description, page
20'-40' (S1012-2) sends a voltage 7:8
US199-2/2 = 0 V
signal to the cab control unit
D2: Diagnostic menu, see section 8 Control
(D790-1). US199-2/5 = 24 V
system, group 8.4.9.4 ATTACH, menu 3
Switch in off position:
US199-2/2 = 24 V
US199-2/5 = 24 V
3 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics, group 11.5.3.1
transmits "automatic spreading out" error shown with error code. Cab control unit (D790-1)
or "automatic spreading in" on the
CAN bus.
4 The attachment control unit (D791-1) - Spreading, function description, page 7:47
activates spreading the same way as
in steps 3-14 of normal spreading.
5 The attachment control unit (D791-1) Buzzer active: U = 24 V Buzzer automatic spreading 20'-40',
activates the automatic spreading description, page 7:70
buzzer (H9003).
D5: Diagnostic menu, see section 8 Control
system, group 8.4.9.21 ATTACH, menu 21

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Hydraulic oil pump 7:53

Pos Explanation Signal description Reference

6 Buzzer automatic spreading (H9003) Buzzer active: U = 24 V Buzzer automatic spreading 20'-40',
generates acoustic warning signal. description, page 7:70
7 When automatic spreading is active, - Section 11 Common electrics, group 11.5.3.12
the KID control unit (D795) activates KID control unit (D795)
the Automatic Spreading event
menu.
8 When the left spreader beam Sensor directly opposite Spreading, function description, page 7:47
approaches the 20', 30' ( ) or 40' indicator plate: U = 24 V
30-foot stop, function description, page
mark, the sensor for 20'–40' end
7:50
position left (B769L) sends a voltage
signal to the attachment control unit D8: Diagnostic menu, see section 8 Control
(D791-1), which activates damping system, group 8.4.9.6 ATTACH, menu 6
for the left spreader beam the same
way as in steps 16-22 of normal
spreading.
9 When the right spreader beam Sensor directly opposite Spreading, function description, page 7:47
approaches the 20', 30' ( ) or indicator plate: U = 24 V
30-foot stop, function description, page
40' mark, the sensor for 20'–40'
7:50
end position right (B769R) sends
a voltage signal to the attachment D9: Diagnostic menu, see section 8 Control
control unit (D791-1), which activates system, group 8.4.9.6 ATTACH, menu 6
damping for the right spreader beam
the same way as in steps 16-22 of
normal spreading.
10 When the left spreader beam is Sensor directly opposite Position sensor spreading, description, page
at the 20', 30' ( ) or 40' mark, indicator plate: U = 24 V 7:69
the sensor for end position 30' left D10: Diagnostic menu, see section 8 Control
(B777L) sends a voltage signal to system, group 8.4.9.6 ATTACH, menu 6
the attachment control unit (D791-1).
11 The attachment control unit (D791-1) I = 0 mA Section 11 Common electrics, group 11.5.3.5
cuts off the current to the solenoid Attachment control unit (D791-1)
valve for spreading out left (Y6018L)
D11: Diagnostic menu, see section 8 Control
or the solenoid valve for spreading
system, group 8.4.9.17 ATTACH, menu 17 and
in left (Y6019L).
8.4.9.18 ATTACH, menu 18
12 When the right spreader beam is Sensor directly opposite Position sensor spreading, description, page
at the 20', 30' ( ) or 40' mark, indicator plate: U = 24 V 7:69
the sensor for end position 30' right D12: Diagnostic menu, see section 8 Control
(B777R) sends a voltage signal to system, group 8.4.9.6 ATTACH, menu 6
the attachment control unit (D791-1).
13 The attachment control unit (D791-1) I = 0 mA Section 11 Common electrics, group 11.5.3.5
cuts off the control current the Attachment control unit (D791-1)
solenoid valve for spreading out right
D13: section 8 Control system, group 8.4.9.19
(Y6018R) or the solenoid valve for
ATTACH, menu 16 and 8.4.9.20 ATTACH,
spreading in right (Y6019R).
menu 20

Hydraulic diagram, see section E Schematics group 10 Common

hydraulics, Hydraulic diagram DCF 90-100, electric servo

7.5.1 Hydraulic oil pump

Hydraulic oil pump, general
See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.

7.5.2 Control valve, attachment

Attachment control valve, description
Spreading is regulated by a separate section in the attachment's control
valve. For a more detailed description of the valve and component
locations, see Attachment control valve, description, page 7:38.

Workshop Manual DCF 80-100 VDCF05.01GB

7:54 7 Load handling – Spreading cylinder

Spreader slide
The valve slide controls the direction and speed of spreading. The
valve slide is controlled by a solenoid valve for spreading out and a
solenoid valve for spreading in.
Solenoid valve for spreading out
The solenoid valve for spreading out controls pressure to the spreader
spool so that it opens and pressurises the spreader cylinder.
The servo valve is controlled electrically with the Solenoid valve,
spreading out left (Y6018L) or Solenoid valve, spreading out right
(Y6018R) which is activated by the Attachment control unit (D791-1).
The servo valve directs servo pressure to the spreader slide
proportional to the control current to the solenoid valve.
The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.13 ATTACH, menu 17
• Right: section 8 Control system, group 8.4.9.15 ATTACH, menu 19
Solenoid valve for spreading in
The solenoid valve for spreading in controls pressure to the spreader
spool so that it opens and pressurises the spreader cylinder.
The servo valve is controlled electrically with the Solenoid valve,
spreading in left (Y6019L) or Solenoid valve, spreading in right
(Y6019R) which is activated by the Attachment control unit (D791-1).
The servo valve directs servo pressure to the spreader slide
proportional to the control current to the solenoid valve.
The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.14 ATTACH, menu 18
• Right: section 8 Control system, group 8.4.9.16 ATTACH, menu 20

Control valve attachment, replacement

See Control valve attachment, replacement, page 7:39.

7.5.3 Spreading cylinder

Spreading cylinder, description
The spreading cylinders move the spreader beams in and out
of the attachment's main beam. The attachment control unit
(D791-1) sends a signal to the attachment control valve which
pressurises the spreading cylinders.
The spreader cylinders are fastened in the spreader beams and
the main beam.
Openings in the sides of the spreader beams and the
attachment's main beam make it possible to access the spreader
cylinders for maintenance purposes.
009925
014816

Spreader cylinders Spreader cylinders, attachment with levelling

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Spreader beam 7:55

7.5.4 Spreader beam

Spreader beam, description
The spreader beams are the part of the attachment that grips
the container Two spreader beams run in the main beam. The
spreader beams are pushed in and out by the hydraulic cylinders.
The spreader beam houses twistlocks, see Twistlocks, function
description, page 7:81 or Lifting hook, description, page 7:93.

009926
014737

Spreader beams Spreader beams, attachment with levelling

Spreader beam slide plates, adjusting/replacing

1 Park the machine with the attachment lowered as far as possible
and spreading extended approx. 1000 mm.
2 Switch off the engine and switch off the main electric power.

1000 mm
013683

3 Unscrew the nuts and bolts (position 1) that secure the slide plates.

1
013684

Workshop Manual DCF 80-100 VDCF05.01GB

7:56 7 Load handling – Spreader beam

4 Remove the slide plates and shims from the main beam.
Lift the extension section slightly so that the slide the plates are
unloaded.

013685

Right side
013686

Left side

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Spreader beam 7:57

5 Refit the slide plates, add a sufficient number shims under the
slide plates so that the play between the slide plates and the main
beam is 1-3 mm both laterally and vertically. This corresponds
to the measurements X + (1-3) mm and Y + (1-3) mm internally
between the slide plates.

NOTE
Do not use too thick shims. Too little play increases wear on
the slide plates.

NOTE
Check that the attaching bolts for all slide plates are tightened.

6 Start the machine and check the spreading functioning. Try to lift
a container and then check the spreader beams' play again on
the attachment's main beam.
013687

Right side
013688

Left side

Workshop Manual DCF 80-100 VDCF05.01GB

7:58 7 Load handling – Spreader beam

Slide plates spreader beam for attachment with

levelling, adjusting/replacing

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

and spreading run all the way in.

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

1 3 Unload the tension from the slide plate in question.

The pressure can be relieved from the slide plates by raising the
outer edge of the spreader beam or inserting wedges to alter the
position of the spreader beam in the attachment's main beam.
4 Remove the attaching bolts for the slide plate's bracket.
5 Remove the slide plate's guide screw.
6 Pull out the slide plate with spacer plate and bracket.
7 Measure the thickness of the slide plate. Replace if necessary.

2 NOTE
The thickness of the slide plate should be at least 10 mm.

8 Place the slide plate in the correct position.

Check the clearance between spreader beam and slide plate. The
play should be less than 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.

NOTE
009189

In general, the upper slide plates on the front of the spreader

1 beam/main beam and the lower slide plates on the rear of the
The illustration shows the inner slide plates on the side spreader beam/main beam are adjusted with shim plates.
lift attachment's spread beam.
1. Slide plates
NOTE
2. Fastening and guide screws for slide plates
Do not use too thick shims. Too little play increases wear on
the slide plates.

NOTE
Check that the attaching bolts for all slide plates are tightened.

9 Fit the slide plate bracket.

10 Fit the slide plate steering screw.
11 Check that the sliding surface is clean and lubricate the sliding
surface on the spreader beam.
12 Start the machine and check the spreading functioning. Try to lift
a container and then check the spreader beams' play again on
the attachment's main beam.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Main beam, side lift attachment 7:59

7.5.5 Main beam, side lift attachment

Side lift attachment's main beam, description
The main beam side lift attachment is fastened to the trolley by
the hydraulic cylinders. The main beam contains equipment for
spreading (spreader beams, hydraulic cylinders, slide plates
and sensors).

009927
014817

Main beam Main beam, attachment with levelling

Side lift attachment, removing

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

NOTE
It is possible to remove the trolley and the side lift attachment as
a unit.

1 Park the machine with the mast vertical and the attachment in
its lowest position.

2 Turn off engine.

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

a secure manner.
4 Start the engine and lift slightly with the lifting equipment (overhead
crane). Let the machine stand with the ignition on for a while.
5 Turn off engine.
014819

Workshop Manual DCF 80-100 VDCF05.01GB

7:60 7 Load handling – Main beam, side lift attachment

6 Detach the side shift cylinder from the attachment.

Remove the cylinder's shaft from the bracket on the trolley. If
necessary, use the threaded hole and a puller to press the shaft
out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the trolley. Turn off engine.
Save the circlips. Refit the shaft in the cylinder.

013654
7 Fasten the side shift cylinder.
8 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
9 Turn the start key to position 0 and switch off the main power.
009997

10 Mark up and detach hydraulic connections from the side lift

attachment and the side shift cylinder.

NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
009952

VDCF05.01GB Workshop Manual DCF 80-100

7 Load handling – Main beam, side lift attachment 7:61

11 Detach the cable harness of the attachment from the attachment

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

12 Loosen the attachment's mounting unit in the trolley.

13 Lift aside the side lift attachment. Position so as not to damage
the twistlocks/lock tongues.
013680

Workshop Manual DCF 80-100 VDCF05.01GB

7:62 7 Load handling – Main beam, side lift attachment

Side lift attachment, installing

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

1 Park the machine with the mast vertical.

2 Lower the trolley to its lowest position.

3 Turn off 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 switch off the main power.

6 Lift the side lift attachment into place.

Lifting points side lift attachment

7 Fit the lifting carriage's front panels to fix the side lifting attachment
in position.
8 Check that the side lift attachment runs correctly in the
trolley; see Slide plates between trolley and attachment,
adjustment/replacement, page 7:43.
013680

9 Clean and apply a layer of lubricating grease to the side shift

cylinder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment.
Align the side shift cylinder, press in the shaft and secure with
the circlips.

NOTE
Use an anti-recoil plastic or copper mallet.

If necessary, detach the hydraulic connections on the side shift

013654

cylinder to make it possible to adjust cylinder length.

VDCF05.01GB Workshop Manual DCF 80-100

7 Load handling – Main beam, side lift attachment 7:63

11 Attach the cable harness of the attachment to the attachment

control unit.
Lubricate the connectors with contact grease and join them up.
Fasten the wiring with clamps.

12 Remove plugs and connect hydraulic hoses for the side lift
attachment and side shift cylinder using the markings as a guide.
13 Turn on the power supply and start the engine.
14 Check that the hydraulic connections are sealed tightly.
15 Check the functions of the side lift attachment.
009952

16 Check the oil level in hydraulic oil tank when all hydraulic cylinders
are in the retracted position. The oil level should be at the top of
the sight glass. Top up if necessary.

CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic cylinders
fully retracted.

Workshop Manual DCF 80-100 VDCF05.01GB

7:64 7 Load handling – Main beam, side lift attachment

Side lift attachment with levelling, removing

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

NOTE
It is possible to remove the trolley and the side lift attachment as
a unit.

1 Park the machine with the mast vertical and the attachment in
its lowest position.

2 Turn off engine.

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

a secure manner.
4 Start the engine and lift slightly with the lifting equipment (overhead
crane). Let the machine stand with the ignition on for a while.
5 Turn off engine.
009998

6 Detach the side shift cylinder from the attachment.

Remove the cylinder's shaft from the bracket on the trolley. If
necessary, use the threaded hole and a puller to press the shaft
out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the trolley. Turn off engine.
Save the circlips. Refit the shaft in the cylinder.
009951

7 Fasten the side shift cylinder.

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

VDCF05.01GB Workshop Manual DCF 80-100

7 Load handling – Main beam, side lift attachment 7:65

10 Mark up and detach hydraulic connections from the side lift

attachment and the side shift cylinder.

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

009952
11 Detach the cable harness of the attachment from the attachment
control unit.
Undo the connectors and protect the terminals by lubricating them
with contact grease. Then loosely insert the connectors.
Remove the cable harness clamping ring.

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

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:66 7 Load handling – Main beam, side lift attachment

13 Lift aside the side lifting attachment. Position it so that the

twistlocks/lock tongues are not damaged.

009999
Side lift attachment with levelling, installing

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

1 Park the machine with the mast vertical.

2 Lower the trolley to its lowest position.

3 Turn off 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 switch off the main power.

6 Lift the side lift attachment into place.

009999

VDCF05.01GB Workshop Manual DCF 80-100

7 Load handling – Main beam, side lift attachment 7:67

7 Fit the lifting carriage's front panels to fix the side lifting attachment
in position.
8 Check that the side lift attachment runs correctly in the
trolley; see Slide plates between trolley and attachment,
adjustment/replacement, page 7:43 and Slide plates in the trolley
with mechanical levelling, adjusting/replacing, page 7:45.

010000
9 Clean and apply a layer of lubricating grease to the side shift
cylinder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment.
Align the side shift cylinder, press in the shaft and secure with
the circlips.

NOTE
Use an anti-recoil plastic or copper mallet.

If necessary, detach the hydraulic connections on the side shift

cylinder to make it possible to adjust cylinder length.
009951

11 Attach the cable harness of the attachment to the attachment

control unit.
Lubricate the connectors with contact grease and connect them
Fasten the wiring with clamps.

Workshop Manual DCF 80-100 VDCF05.01GB

7:68 7 Load handling – Main beam, side lift attachment

12 Remove plugs and connect hydraulic hoses for the side lift
attachment and side shift cylinder using the markings as a guide.
13 Turn on the power supply and start the engine.
14 Check that the hydraulic connections are sealed tightly.
15 Check the functions of the side lift attachment.

009952
16 Check the oil level in hydraulic oil tank when all hydraulic cylinders
are in the retracted position. The oil level should be at the top of
the sight glass. Top up if necessary.

CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic cylinders
fully retracted.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Position sensor, spreading 7:69

7.5.6 Position sensor, spreading

Position sensor spreading, description
The spreading position sensors indicate the position of the spreader
3 4 5 beams. The position sensors are used to control spreading so that
the twistlocks/lock tongues fit the container. The position sensors
are located under the protective plate at the rear of the attachment's
main beam.

End position sensor 20' and 40' (B769R and B769L) indicates the
end position for 20 and 40 feet containers. The sensor detects the
spreader beam end positions via two indicator plates on the top of the
1 2 spreader beams. The sensor is used to activate damping.

5 4 3 With the 30 feet stop option, two extra sensors are fitted, Sensor end
position 30' (B777R and B777L), and two indicator plates. The sensor
is used to activate 30-foot stop.

The sensors are supplied power by and send a 24 V signal to Control

unit, attachment (D791-1) when the indicator plates pass the sensor.
Indicator plates on the spreader units are mounted so that the sensors
generate a signal when the spreader unit passes the sensor. The
indicator plates and the position of the sensors are designed so that
013676

2 1 the distance between the spreaders becomes 20' (30') and 40'.

1. Sensor, end position 20' and 40' The signals can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.6 ATTACH, menu 6.
2. Sensor end position 30'
3. Indicator plate 20'
4. Indicator plate 30'
5. Indicator plate 40'

3 4 5
2
1

2
1
009928

4 3
5
Attachment with levelling
1. Sensor, end position 20' and 40'
2. Sensor end position 30'
3. Indicator plate 20'
4. Indicator plate 30'
5. Indicator plate 40'

Position sensor, checking and adjustment

See Position sensor, adjusting, page 7:4.

Workshop Manual DCF 80-100 VDCF05.01GB

7:70 7 Load handling – Buzzer, automatic spread 20'-40'

7.5.7 Buzzer, automatic spread 20'-40'

Buzzer automatic spreading 20'-40', description

The buzzer for automatic spread 20'-40' (H9003) sits on the underside
of the trolley on machines with automatic spreading 20'-40'. The buzzer
is activated during automatic spreader movement.

7.5.8 Pipes and hoses

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

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Tilt 7:71

7.7 Tilt
Tilt, function description
Condition Reference value Reference
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage

D5

5b 5a 6
D790-1
10
D797-1 11
7
D7
8
10
11
P A1

B1
T1
P PS 9
3
4

EF
C P

1 1

009957
Pos Explanation Signal description Reference
1 The hydraulic oil pumps pump oil from See the pressure plate on Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. the left-hand frame beam. Axial piston pump with variable displacement
2 The pressure reducer reduces the See the pressure plate on Pressure reducer, description, page 7:12
pressure from one of the hydraulic the left-hand frame beam.
pumps to servo pressure.
3 The accumulator stores servo pressure. See the pressure plate on Accumulator servo circuit, description, page
The non-return valve in the pressure the left-hand frame beam. 7:13
reducer makes it possible to store the
pressure when the engine is switched
off.
4 The servo filter cleans the oil upstream - Servo filter, description, page 7:12
of the lift and tilt control valve.

Workshop Manual DCF 80-100 VDCF05.01GB

7:72 7 Load handling – Tilt

Pos Explanation Signal description Reference

5a The tilt control lever (R8072-P2) sends U = 0.5-4.5 V Control levers for electric servo, description,
the cab control unit (D790-1) a voltage page 7:5
Out: U = <2.5 V
signal proportional to lever movement.
D5: Diagnostic menu, see section 8 Control
In: U = >2.5 V
system, group 8.4.8.1 ELSERV, menu 1
0.5 V is the highest tilt
out speed and 4.5 V is
the highest tilt in speed.
Lower voltage than 0.5 V
and higher voltage than
4.5 V is used to detect
faults in cable harnesses
and controls.
5b The control lever (S815-P2) sends the US815-P2 = 0.5-4.5 V Control lever, description, page 7:6
cab control unit (D790-1) a voltage
In: US815-P2 <2.5 V D5: Diagnostic menu, see section 8 Control
signal proportional to lever movement.
system, group 8.4.8.1 ELSERV, menu 1
Out: US815-P2 = >2.5 V
0.5 V is the highest tilt
in speed and 4.5 V is
the highest tilt out speed.
Lower voltage than 0.5 V
and higher voltage than
4.5 V is used to detect
faults in cable harnesses
and controls.
6 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
tilt in or tilt out on the CAN bus. system, error shown with Cab control unit (D790-1)
error code.
7 The frame control unit (D797-1) activates U = 24 V Section 11 Common electrics, group 11.5.3.2
the servo valve for tilt in (Y6011) or the Frame control unit (D797-1)
servo valve for tilt out (Y6010).
D7: Diagnostic menu, see section 8 Control
system, group 8.4.8.5 ELSERV, menu 5 and
8.4.8.6 ELSERV, menu 6
8 The solenoid valve for tilt in (Y6011) or - Control valve, lift and tilt, description, page
the solenoid valve for tilt out (Y6010) 7:14
pressurises the tilt spool in the lift and
tilt control valve.
9 The control valve's tilt spool changes - Control valve, lift and tilt, description, page
position and pressurises the load 7:73
retention valve.
10 The load retention valve opens and - Load holding valve, description, page 7:74
directs the pressure on to the tilt
cylinders.
11 The tilt cylinders angle the mast in - Tilt cylinder, description, page 7:74
relation to the frame.
Mast, description, page 7:18

Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics, Hydraulic diagram DCF 80-100, electric servo

VDCF05.01GB Workshop Manual DCF 80-100

7 Load handling – Hydraulic oil pump 7:73

7.7.1 Hydraulic oil pump

Hydraulic oil pump, general
See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.

7.7.2 Accumulator
Accumulator, description
See section 10 Common Hydraulics, group 10.3.2 Accumulator.

7.7.3 Pressure reducer

Pressure reducer, description
See Pressure reducer, description, page 7:12.

7.7.4 Servo filter

Servo filter, description
See Servo filter, description, page 7:12.

7.7.5 Control valve, lift and tilt

Control valve, lift and tilt, description
Tilt is controlled by a separate section of the lift and tilt control valve.
See also Control valve, lift and tilt, description, page 7:14.

For more information about tilting, see Tilt, function description, page
7:71.
Tilt slide
When the solenoid valves are activated, the tilt spool is pressurised
and controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.
Solenoid valve, tilt out
On machines with electric servo, the solenoid valve tilt out is controlled
electrically with Solenoid valve tilt out (Y6010) which is activated by the
Frame control unit option (D797-1). The solenoid valve directs servo
pressure to the tilt spool which is proportional to the control current to
the solenoid valve.

The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.8.6 ELSERV, menu 6.
Solenoid valve, tilt in
On machines with electric servo, the solenoid valve tilt in is controlled
electrically with Solenoid valve tilt in (Y6011) which is activated by the
Frame control unit option (D797-1). The solenoid valve directs servo
pressure to the tilt spool which is proportional to the control current to
the solenoid valve.

The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.8.5 ELSERV, menu 5.

Workshop Manual DCF 80-100 VDCF05.01GB

7:74 7 Load handling – Load retention valve

7.7.6 Load retention valve

Load holding valve, description
Load retention valves are located on the tilt cylinders by the hydraulic
connection to the rod side. The load retention valve prevents the
tilt cylinders from moving faster than the supplied pressure from the
load handling control valve. This prevents unwanted tilting forward
that can occur with heavy loads and or high lifting. The load retention
valve also makes the tilt movement more controlled.

009929

Load retention valve

7.7.7 Tilt cylinder

Tilt cylinder, description
The tilt cylinders sit between the mast and the frame and angle the
mast in relation to the machine.

2
009930

1. Tilt cylinder
2. Mast
3. Lower mast mounting in frame

Hydraulic cylinders, repairs

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Mast 7:75

7.7.8 Mast
Mast, description
See Mast, description, page 7:18.

7.7.9 Pipes and hoses

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:76 7 Load handling – Levelling

7.8 Levelling
Mechanical levelling, function description
Mechanical levelling is possible because the attachment's main beam
is movably suspended over the slide plates in the main beam. A lateral
clearance allows for mechanical levelling 3°. Mechanical levelling
means that the attachment is in a float position and adapts to the angle
of the container to be lifted.

Active levelling, function description

Condition Reference value Reference

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

1b 1a
D1

2 11
+ D790-1

D797-1 D791-1
3 8 D3
D2
9 11
C

P1 A

4
T1 B

10
5

C
6
7
014800

Pos Explanation Signal description Reference

1a The levelling control lever U = 0.5-4.5 V Control levers for electric servo, description,
(R8075-1-P5) sends a voltage page 7:5
Left: U = <2.5 V
signal to the cab control unit (D790-1).
D1: Diagnostic menu, see section 8 Control
Right: U = 2.5 V
system, group 8.4.9.2 ATTACH, menu 2
1b Control lever S815-P3 transmits a US815-P3 = 0.5-4.5 V Control lever, description, page 7:6
voltage signal proportional to lever
Left: US815-P3 <2.5 V D1: Diagnostic menu, see section 8 Control
movement while control lever S815-P4
system, group 8.4.9.1 ELSERV, menu 1
sends voltage to the cab control unit Right: US815-P3 = >2.5 V
(D790-1).
US815-T4 = 24 V
2 Control unit, cab (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
side shift left or right on the CAN bus. system, error shown with Cab control unit (D790-1)
error code.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Hydraulic oil pump 7:77

Pos Explanation Signal description Reference

3 The frame control unit (D797-1) U = 24 V Section 11 Common electrics, group 11.5.3.2
activates the solenoid valve for main Frame control unit (D797-1)
pump relief (Y6062-2).
D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 The solenoid valve for main pump - Valve block, main pump relief, description,
relief (Y6062-2) routes a relieved page 7:46
constant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
5 The attachment shuttle valve sends - Section 10 Common hydraulics, group 10.5.3
the load signal on to the hydraulic oil Shuttle valve
pump for load handling or the cab tilt
shuttle valve.
The cab tilt shuttle valve sends the - Section 10 Common hydraulics, group 10.5.3
6 load signal on to the hydraulic oil pump Shuttle valve
for load handling.
7 The hydraulic oil pump for load See the pressure plate on Section 10 Common hydraulics, group 10.4.2
handling pumps oil from the hydraulic the left-hand frame beam. Axial piston pump with variable displacement
oil tank.
8 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group 11.5.3.5
activates the solenoid valve for Attachment control unit (D791-1)
levelling right (Y6035) or the solenoid
D8: Diagnostic menu, see section 8 Control
valve for levelling left (Y6036).
system, group 8.4.9.13 ATTACH, menu 13 and
8.4.9.14 ATTACH, menu 14
9 The solenoid valve for levelling right - Attachment control valve, description, page
(Y6035) or the solenoid valve for 7:38
levelling left (Y6036) pressurises
the levelling spool in the attachment
control valve.
10 The control valve's levelling slide - Attachment control valve, description, page
changes position and pressurises the 7:38
levelling cylinders.
11 The levelling cylinders push in the side - Levelling cylinder, description, page 7:79
lifting attachments sideways in relation
to the lifting carriage.

Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics, Hydraulic diagram DCF 80-100, electric servo

7.8.1 Hydraulic oil pump

Hydraulic oil pump, general
See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.

7.8.2 Control valve, attachment

Attachment control valve, description
Levelling is controlled by a separate section of the attachment control
valve. For a general description of the valve and component locations,
see Attachment control valve, description, page 7:38.
Levelling slide
The valve slide controls the direction and speed of attachment levelling.

The valve spool is controlled by a solenoid valve for levelling right

(Y6035) and a solenoid valve for levelling left (Y6036).

Workshop Manual DCF 80-100 VDCF05.01GB

7:78 7 Load handling – Control valve, attachment

Solenoid valve, levelling right

The solenoid valve for levelling right controls pressure to the levelling
spool so that it opens and pressurises the levelling cylinders.

Solenoid valve, levelling right is controlled electrically by Solenoid

valve, levelling right (Y6035), which is activated by Control unit,
attachment (D791-1). The solenoid valve controls the servo-pressure
to the levelling slide.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.16 ATTACH, menu 16.
Solenoid valve, levelling left
The solenoid valve for levelling left controls pressure to the levelling
spool so that it opens and pressurises the levelling cylinders.

Solenoid valve, levelling left is controlled electrically by Solenoid valve,

levelling left (Y6036), which is activated by Control unit, attachment
(D791-1). The solenoid valve controls the servo-pressure to the
levelling slide.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.16 ATTACH, menu 16.

Control valve attachment, replacement

See Control valve attachment, replacement, page 7:39.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Levelling cylinder 7:79

7.8.3 Levelling cylinder

Levelling cylinder, description

The levelling cylinders sit between the lifting carriage and the side
lifting attachment. They change the angle of the side lifting attachment
in relation to the machine.

009924

Levelling cylinders

Hydraulic cylinders, repairs

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

7.8.4 Trolley
Trolley, description
See Trolley, description, page 7:28

7.8.5 Valve block, main pump relief

Valve block, main pump relief, description
See Valve block, main pump relief, description, page 7:46

7.8.6 Pipes and hoses

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

Workshop Manual DCF 80-100 VDCF05.01GB

7:80 7 Load handling – Load carrier

7.9 Load carrier

7.9.1 Twistlocks
Twistlocks, description
The container is held in place on the side lift attachment with two
twistlocks.

Twistlocks are controlled with Switch twistlocks. A section of the

attachment control valve pressurises two parallel-connected cylinders,
one on each side of side lift attachment. Each hydraulic cylinder
actuates a linkage that turns a twistlock. Four position sensors, two on
each side of the side lift attachment, detect the position of the linkage
and indicates whether the twistlocks are open or locked. Indicator
lamps on the side lift attachment and in the cab, and a mechanical
indicator on the side lift attachment shows the status of the twistlocks.

A contact pin and a sensor by each twistlock indicates when the

attachment is in contact with the container. This is used to control
when the twistlocks can be actuated. An indicator light on the side lift
attachment and one in the cab indicate when the side lift attachment is
fully aligned. An event menu shows which twistlocks is aligned (1 - 2).
Both twistlocks must be aligned in order to actuate the twistlocks.

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Twistlocks 7:81

Twistlocks, function description

Condition Reference value Reference

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage
Alignment Full alignment or bypass Twistlocks, description, page 7:86
activated
Section 8 Control system, group 8.2.2 Bypassing

2b 1 D1

20
2a
8 7,22
D2 5,23
D790-1 D790-2 D795
D6 D20
D797-1 D791-1 D3
4,6,14, 21
9
D14
D9 19
15 D19 18 3

P1 A

D10
10 B
T1
17
16
11 18 3
19
D6

13 12

014801
Pos Explanation Signal description Reference
1 The switch for locking the twistlocks U = 24 V Switch, lock twistlock/lock tongue,
(S1003) (automatic mode) sends a description, page 7:7
voltage signal to the cab control unit
D1: Diagnostic menu, see section 8 Control
(D790-1).
system, group 8.4.9.5 ATTACH, menu 5
2a The switch for opening the twistlocks U = 24 V Switch, lock twistlock/lock tongue,
(S1002) sends a voltage signal to the description, page 7:7
cab control unit (D790-1) for twistlock
D2: Diagnostic menu, see section 8 Control
opening.
system, group 8.4.9.5 ATTACH, menu 5
If the "lock twistlocks" switch (S1003) is
in the manual position, a signal from the
"open twistlocks" switch (S1002) is not
needed to open the twistlocks.

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7:82 7 Load handling – Twistlocks

Pos Explanation Signal description Reference

2b The control lever (S815-T2) sends a US815/T2 = 24 V Control lever, description, page 7:6
voltage signal to the cab control unit
D2: Diagnostic menu, see section 8 Control
(D790-1) for twistlock opening.
system, group 8.4.9.3 ATTACH, menu 3
If Switch, lock twistlocks (S1003) is
in manual position then no signal is
required from the control lever to open
twistlocks.
3 The alignment left sensor (B7203L) and Sensor directly opposite Sensor, alignment, description, page 7:88
alignment right sensor (B7203R) detect indicator plate: U = 24 V
D3: Diagnostic menu, see section 8 Control
position and send a voltage signal to the
system, group 8.4.9.6 ATTACH, menu 6
attachment control unit (D791).
4 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits alignment on the CAN bus. system, error shown with Attachment control unit (D791-1)
error code.
5 Control unit KID (D795) activates the - Section 11 Common electrics, group
event menu for alignment. 11.5.3.12 KID control unit (D795)
6 The attachment control module (D791) U = 24 V D6: Diagnostic menu, see section 8 Control
activates the alignment indicator light on system, group 8.4.9.10 ATTACH, menu 10
the mast light panel.
7 Control unit KID (D790-2) activates the - Section 11 Common electrics, group
indicator light for alignment on the cab's 11.5.3.11 KIT control unit (D790-2)
light panel.
8 Control unit, cab (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
"open twistlocks" or "lock twistlocks" on system, error shown with Cab control unit (D790-1)
the CAN bus. error code.
9 The frame control unit (D797-1) activates U = 24 V Section 11 Common electrics, group 11.5.3.2
the solenoid valve for main pump relief Frame control unit (D797-1)
(Y6062-2).
D9: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
10 The solenoid valve for main pump relief - Valve block, main pump relief, description,
(Y6062-2) routes a relieved constant page 7:46
pressure to the hydraulic oil pump for
D10: Diagnostic menu, see section 8 Control
load handling. This serves as a load
system, group 8.4.5.6 HYD, menu 6
signal.
11 The attachment shuttle valve sends the - Section 10 Common hydraulics, group
load signal on to the hydraulic oil pump 10.5.3 Shuttle valve
for load handling or the cab tilt shuttle
valve.
12 The cab tilt shuttle valve sends the load - Section 10 Common hydraulics, group
signal on to the hydraulic oil pump for 10.5.3 Shuttle valve
load handling.
13 The hydraulic oil pump for load handling See the pressure plate on Section 10 Common hydraulics, group 10.4.2
pumps oil from the hydraulic oil tank. the left-hand frame beam. Axial piston pump with variable displacement
14 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group 11.5.3.5
activates the "open twistlocks" solenoid Attachment control unit (D791-1)
valve (Y6039) or the "lock twistlocks"
D14: Diagnostic menu, see section 8 Control
solenoid valve (Y6040).
system, group 8.4.9.9 ATTACH, menu 9
15 The "open twistlocks" solenoid valve - Attachment control valve, description, page
(Y6039) or the "lock twistlocks" solenoid 7:38
valve (Y6040) pressurises the twistlock
D15: Diagnostic menu, see section 8 Control
spool with servo pressure.
system, group 8.4.9.9 ATTACH, menu 9
16 The twistlock spool of the control valve - Attachment control valve, description, page
changes position and pressurises the 7:38
lock cylinders via the overcentre valve.
17 The overcentre valve prevents the -
uncontrolled opening or closing of the
twistlocks.

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 7 Load handling – Twistlocks 7:83

Pos Explanation Signal description Reference

18 The lock cylinders rotate the twistlocks. - Lock cylinder, description, page 7:98
19 The "unlocked twistlocks" sensor (B7204 Sensor directly opposite Sensor, twistlocks, description, page 7:90
L and R) or the "locked twistlocks" sensor indicator plate: U = 24 V
D19: Diagnostic menu, see section 8 Control
(B7205 L and R) sends a signal to the
system, group 8.4.9.7 ATTACH, menu 7
attachment control unit (D791).
20 The attachment control unit (D791-1) U = 24 V D20: Diagnostic menu, see section 8 Control
supplies voltage to the "unlocked system, group 8.4.9.10 ATTACH, menu 10
twistlocks" indicator light (H562) or the
"locked twistlocks" indicator light (H563)
on the mast light panel.
21 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits "twistlocks unlocked" or system, error shown with Attachment control unit (D791-1)
"twistlocks locked" on the CAN bus. error code.
22 Control unit KIT (D790-2) supplies - Section 11 Common electrics, group
voltage to Indicator light "unlocked 11.5.3.11 KIT control unit (D790-2)
twistlocks" or Indicator light "locked
twistlocks" on the cab lamp panel.
23 Control unit KID (D795) activates the - Section 11 Common electrics, group
event menu for twistlocks. 11.5.3.12 KID control unit (D795)

Hydraulic diagram, see section E Schematics 10 Common hydraulics,

Hydraulic diagram DCF 90-100, electric servo

7.9.1.1 Hydraulic oil pump

Hydraulic oil pump, general

See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.

7.9.1.2 Control valve, attachment

Attachment control valve, description

The twistlocks function is regulated by a separate section in the
attachment's control valve. For a general description of the valve
and component locations, see Attachment control valve, description,
page 7:38.
Twistlocks slide, description
The valve spool controls the direction of the lock cylinder.

The valve spool is controlled by the "lock twistlocks" solenoid valve

(Y6040) and the "open twistlocks" solenoid valve (Y6039).
"Lock twistlocks" solenoid valve, description
The "lock twistlocks" solenoid valve directs pressure to the twistlock
spool so that the spool opens and pressurises the lock cylinders.

Solenoid valve lock twistlocks is controlled electrically by Solenoid

valve, lock twistlocks (Y6040), which is activated by Control unit,
attachment (D791-1). The solenoid valve then directs servo pressure
to the twistlock spool.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.9 ATTACH, menu 9.

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7:84 7 Load handling – Twistlocks

"Open twistlocks" solenoid valve, description

The "open twistlocks" solenoid valve directs pressure to the twistlock
spool so that the spool opens and pressurises the lock cylinders.

Solenoid valve open twistlocks is controlled electrically by Solenoid

valve, open twistlocks (Y6039), which is activated by Control unit,
attachment (D791-1). The solenoid valve then directs servo pressure
to the twistlock spool.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.9 ATTACH, menu 9.

Control valve attachment, replacement

See Control valve attachment, replacement, page 7:39.

7.9.1.3 Twistlock overcentre valve

Twistlock overcentre valve, description

The overcentre valve prevents the uncontrolled opening or
closing of the twistlocks. The valve is located to the left of the
attachment control valve on the trolley.
014805

009931

Attachment with levelling

VDCF05.01GB Workshop Manual DCF 80-100

 7 Load handling – Twistlocks 7:85

7.9.1.4 Lock cylinder

Lock cylinder, description

The lock cylinder activates the lock mechanism so that the
twistlocks are rotated. Two parallel-connected locking cylinders,
one on the right and one on the left spreader beam actuate a
linkage that turns a twistlock.

014811
014806

Attachment with levelling

Hydraulic cylinders, repairs

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

7.9.1.5 Lock mechanism

Lock mechanism, description

The lock mechanism transfers the force of the lock cylinders to the
1
twistlocks. Two lock mechanisms, one in the right and one in the left
spreader beam, actuate the twistlocks. The lock mechanism runs in
3 the corner box.
2
The lock mechanism consists of a rotary plate with a linkage bearing
at which the lock cylinder is attached. The rotary plate rotates the
twistlocks.
014807

1. Linkages
2. Rotary plate
3. Lock cylinder mount

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7:86 7 Load handling – Twistlocks

7.9.1.6 Twistlocks

Twistlocks, description
1 2 3
WARNING
Dropped load.
Extreme danger!
Twistlocks hold the load during load handling and
therefore it is of the utmost importance that twistlocks
are checked according to instructions and are replaced
at the slightest sign of damage or wear.

5 4 014716

Twistlocks secure the load and are located out in the corners of the
1. Unlocked twistlock sensor spreader beam's longitudinal section.

2. Sensor, alignment Twistlocks are manufactured from high-strength steel in accordance

3. Locked twistlock sensor with international standards. The lift pins are marked with serial
numbers.
4. Lift pin
5. Alignment pin Twistlocks are connected via a linkage system to a hydraulic cylinder
which in turn is controlled via a section in the attachment's control
valve. Inductive sensors send signals when the twistlocks are locked
and unlocked, respectively.

VDCF05.01GB Workshop Manual DCF 80-100

7 Load handling – Twistlocks 7:87

Twistlocks, replacement
1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

3 Clean the twistlocks and the surrounding area.

4 Slacken the screws on the clamp holding the twistlocks in place.

5 Hold the twistlocks while removing the clamp halves.

WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
014821

6 Remove the clamp halves and lift away the twistlock.

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

NOTE
Remember the washer.

8 Check the positions of the parts and that the twistlocks can move.

9 Tighten the screws of the clamp halves.

10 Lubricate the twistlocks and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlocks are working.
014821

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7:88 7 Load handling – Twistlocks

7.9.1.7 Sensor, alignment

Sensor, alignment, description

The alignment sensors (B7203L and B7203R) detect when the
attachment has contact with the container. Two inductive position
sensors are used to indicate alignment.
The sensor senses the position of a spring pin which is pressed
in when the attachment has contact up against the container. The
sensor is located behind the pin. The position of the sensor can
be adjusted so that it gives a signal when the pin is pressed in
and the head is level with the lower edge of the spreader beam.
The clearance between the attachment and the container's
corner boxes means the sensors stop sending signals when the
attachment is lifted.
The sensors are supplied power and send a 24 V signal to
the attachment control unit (D791-1) when the indicator pin is
pressed in.
The signal can be checked via the diagnostic menu. See section
8 Control system, group 8.4.9.7 ATTACH, menu 7.

014812

1 2
014813

1 2 Attachment with levelling

1. Sensor, alignment 1. Sensor, alignment
2. Alignment pin 2. Alignment pin

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 7 Load handling – Twistlocks 7:89

Alignment sensor, checking and adjusting

1 Check that the alignment pins in the corner boxes can move up
and down freely. The alignment pins must spring down when they
are not loaded.
2 Check that the sensor is free of damage and dirt.
3 Turn the start key to position I and check that the LED on the
sensor is unlit.
4 Lower the attachment onto a container and check that the
alignment indicator light comes on.
5 Lift the container a little bit so that the alignment indicator light
goes out.

014717
6 With the container lifted, check how much alignment pin movement
1 2 is needed to detect contact (LED on the sensor lights). The
movement should be 3–4 mm.
Right side
1. Sensor, alignment
2. Alignment pin

7 If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the alignment pin is 5±1 mm.
014718

2 1

Left side
1. Sensor, alignment
2. Alignment pin

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7:90 7 Load handling – Twistlocks

7.9.1.8 Sensor twistlocks

Sensor, twistlocks, description

Twistlock sensors (B7204L, B7204R, B7205L and B7205R)
detect when the twistlocks are locked or unlocked. Four inductive
position sensors, two in each spreader beam, detect the position
of the lock mechanism.
Both sides function in the same way independently of one
another. An indicator plate is fitted on the lock mechanism by the
lock cylinder. When the lock mechanism is in the position that
locks the twistlocks, one of the sensors sends a signal to Control
unit, attachment (D791-1). When the lock mechanism is in the
position that unlocks the twistlocks, the second sensor sends
signal to Control unit, attachment (D791-1). No signals are sent if
the lock mechanism stops midway.
The sensors are supplied power by and send a 24 V signal to
Control unit, attachment (D791-1) when the indicator plate is in
front of the sensor.
The signal can be checked via the diagnostic menu. See section
8 Control system, group 8.4.9.8 ATTACH, menu 8.

014810

1 2
014809

1 2 Attachment with levelling

1. Unlocked twistlock sensor 1. Unlocked twistlock sensor
2. Locked twistlock sensor 2. Locked twistlock sensor

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 7 Load handling – Twistlocks 7:91

Twistlocks sensor, checking and adjusting

1 Check that the sensors are free of damage and dirt.
2 Turn the start key to position I and check that the LED on the
"unlocked twistlock" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 5±1 mm.
3 Check that the "twistlocks open" indicator light is lit.
4 Lower the attachment over a container and lock the twistlocks.
5 Check that the LED on the "locked twistlock" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 5±1 mm.

014719
1 2

Right side
1. Unlocked twistlock sensor
2. Locked twistlock sensor

6 Check that the "twistlocks locked" indicator light is lit.

014720

2 1

Left side
1. Unlocked twistlock sensor
2. Locked twistlock sensor

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7:92 7 Load handling – Twistlocks

7.9.1.9 Valve block, main pump relief

Valve block, main pump relief, description

See Valve block, main pump relief, description, page 7:46

7.9.1.10 Pipes and hoses

Piped and hoses, description

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

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7 Load handling – Lifting hook 7:93

7.9.2 Lifting hook

Lifting hook, description
The container is held in place on the side lifting attachment with
two fixed lifting hooks that are positioned in the corner boxes of the
container (in the side holes on the long side) and two movable lock
tongues that are positioned in the corner boxes of the container (in the
side holes on the short side). These secure that side lifting attachment
to the container.

Lock tongues are controlled with the Switch lock tongues. A section of
the Attachment control valve pressurises the two parallel-connected
hydraulic cylinders, one in each spreader beam. Each hydraulic
cylinder actuates a linkage that turns a lock tongue. Four position
sensors, two in each position sensor, detect the position of the linkage
and indicates whether the lock tongues are open or locked. Indicator
lamps on the side lift attachment and in the cab show the status of
the lock tongues.

The lock tongues are activated manually or automatically and can be

opened if the machine is driven at a speed below 5 km/h. If the lock
tongues are not locked when the attachment is carrying a load, the
speed of the machine's hydraulic functions is limited and machine
speed is limited to max. 5 km/h.

Two detection sensors (one at each lifting hook) use ultrasound to

detect distance (and inform the system) if one or two containers are
to be lifted. At each lifting hook, there is one sensor that indicates
contact with the lower container and one sensor that indicates contact
with the upper container.

Two indicator lights on the side lift attachment and one in the cab
indicate when the side lift attachment is fully aligned. An event menu
shows which lifting hooks are aligned (1-2).

Contact by both of the lifting hooks is not required to activate the lock
tongues. But, unless there is contact and correct locking, the machine's
hydraulic functions and speed will be limited.

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7:94 7 Load handling – Lifting hook

Lifting hook, function description

Condition Reference value Reference

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage
Alignment Full alignment or bypass Lifting hook, description, page 7:101
activated
Section 8 Control system, group 8.2.2 Bypassing

2b 1
D1

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

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

D10 16 D20 D3 19 3

P1 A

18 20
11 B
T1

17
12 19 3
C 4
14 13

014802

Pos Explanation Signal description Reference

1 The switch for locking the lock tongue U = 24 V Switch, lock twistlock/lock tongue,
(S1003) (automatic mode) sends a description, page 7:7
voltage signal to the Cab control unit
D1: Diagnostic menu, see section 8 Control
(D790-1).
system, group 8.4.9.5 ATTACH, menu 5
2a The switch for opening the lock tongue U = 24 V Switch, lock twistlock/lock tongue,
(S1002) sends a voltage signal to the description, page 7:7
cab control unit (D790-1) for lock tongue
D2: Diagnostic menu, see section 8 Control
opening.
system, group 8.4.9.5 ATTACH, menu 5
If the switch for locking the lock tongue
(S1003) is in the manual position, a
signal from the "open lock tongue"
switch (S1002) is not needed to open
the lock tongues.

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 7 Load handling – Lifting hook 7:95

Pos Explanation Signal description Reference

2b The control lever (S815-T2) sends a US815/T2 = 24 V Control lever, description, page 7:6
voltage signal to the cab control unit
D2: Diagnostic menu, see section 8 Control
(D790-1) for lock tongue opening.
system, group 8.4.9.5 ATTACH, menu 5
If the switch for locking the lock tongue
(S1003) is in the manual position, no
signal is needed from the control lever to
open lock tongues.
3 The sensor for lower left alignment Sensor directly opposite Alignment and detection sensor, description,
(B7203LL), sensor for upper left indicator plate: U = 24 V page 7:102
alignment (B7203LU-2), the sensor for
D3: Diagnostic menu, see section 8 Control
lower right alignment (B7203RL) and
system, group 8.4.9.23 ATTACH, menu 23
the sensor for upper right alignment
(B7203RU-2) detect position and send a
voltage signal to the attachment control
unit (D791).
4 The sensor for upper container right - Alignment and detection sensor, description,
detection (B7203RU) and the sensor for page 7:102
upper container left detection (B7203LU)
D4: Diagnostic menu, see section 8 Control
detect position and send a voltage signal
system, group 8.4.9.22 ATTACH, menu 22
to the attachment control unit (D791).
5 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits alignment/detection on the system, error shown with Attachment control unit (D791-1)
CAN bus. error code.
6 Control unit KID (D795) activates the - Section 11 Common electrics, group
event menu for alignment. 11.5.3.12 KID control unit (D795)
7 The attachment control module (D791) U = 24 V D6: Diagnostic menu, see section 8 Control
activates the alignment indicator light system, group 8.4.9.10 ATTACH, menu 10
(H564) on the mast light panel.
8 Control unit KID (D790-2) activates the - Section 11 Common electrics, group
indicator light for alignment on the cab's 11.5.3.11 KIT control unit (D790-2)
light panel.
9 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
"open lock tongue" or "lock lock tongue" system, error shown with Cab control unit (D790-1)
on the CAN bus. error code.
10 The frame control unit (D797-1) activates U = 24 V Section 11 Common electrics, group 11.5.3.2
the solenoid valve for main pump relief Frame control unit (D797-1)
(Y6062-2).
D10: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
11 The solenoid valve for main pump relief - Valve block, main pump relief, description,
(Y6062-2) routes a relieved constant page 7:46
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
12 The attachment shuttle valve sends the - Section 10 Common hydraulics, group
load signal on to the hydraulic oil pump 10.5.3 Shuttle valve
for load handling or the cab tilt shuttle
valve.
13 The cab tilt shuttle valve sends the load - Section 10 Common hydraulics, group
signal on to the hydraulic oil pump for 10.5.3 Shuttle valve
load handling.
14 The hydraulic oil pump for load handling See the pressure plate on Section 10 Common hydraulics, group 10.4.2
pumps oil from the hydraulic oil tank. the left-hand frame beam. Axial piston pump with variable displacement
15 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group 11.5.3.5
activates the "open lock tongue" Attachment control unit (D791-1)
solenoid valve (Y6039) or the "lock lock
D15: Diagnostic menu, see section 8 Control
tongue" solenoid valve (Y6040).
system, group 8.4.9.9 ATTACH, menu 9

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7:96 7 Load handling – Lifting hook

Pos Explanation Signal description Reference

16 The "open lock tongue" solenoid valve - Attachment control valve, description, page
(Y6039) or the "lock lock tongue" 7:38
solenoid valve (Y6040) pressurises the
lock tongue spool with servo pressure.
17 The lock tongue spool of the control - Attachment control valve, description, page
valve changes position and pressurises 7:38
the lock cylinders via pilot-controlled
non-return valves.
18 Pilot-controlled non-return valves - Pilot-controlled non-return valve for lock
prevent the uncontrolled opening or tongue, description, page 7:98
closing of the lock tongues.
19 The lock cylinders rotate the lock - Lock cylinder, description, page 7:98
tongues.
20 The "unlocked lock tongue" sensor Sensor directly opposite Sensor, twistlocks, description, page 7:90
(B7204 L and R) or the "locked lock indicator plate: U = 24 V
D20: Diagnostic menu, see section 8 Control
tongue" sensor (B7205 L and R) sends
system, group 8.4.9.8 ATTACH, menu 8
a signal to the attachment control unit
(D791).
21 The attachment control unit (D791-1) U = 24 V D21: Diagnostic menu, see section 8 Control
supplies voltage to the "unlocked lock system, group 8.4.9.10 ATTACH, menu 10
tongues" indicator light (H562) or the
"locked lock tongues" indicator light
(H563) on the mast light panel.
22 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits "lock tongues unlocked" or system, error shown with Attachment control unit (D791-1)
"lock tongues locked" on the CAN bus. error code.
23 The KIT control unit (D790-2) supplies - Section 11 Common electrics, group
voltage to the "unlocked lock tongues" 11.5.3.11 KIT control unit (D790-2)
indicator light or the "locked lock
tongues" indicator light on the cab light
panel.

Hydraulic diagram, see section E Schematics group 10 Common

hydraulics, Hydraulic diagram DCF 80-100, electric servo

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7 Load handling – Lifting hook 7:97

7.9.2.1 Hydraulic oil pump

Hydraulic oil pump, general

See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.

7.9.2.2 Control valve, attachment

Attachment control valve, description

Lock tongues are regulated by a separate section in the attachment's
control valve. For a general description of the valve and component
locations, see Attachment control valve, description, page 7:38.
Lock tongue spool, description
The valve spool controls the direction of the lock cylinder.

The valve spool is controlled by the "lock lock tongue" solenoid valve
(Y6040) and the "open lock tongue" solenoid valve (Y6039).
"Lock lock tongue" solenoid valve, description
The "lock lock tongue" solenoid valve directs pressure to the lock
tongue spool so that the spool opens and pressurises the lock cylinders.

The valve spool is controlled electrically by Solenoid valve, lock lock

tongues (Y6040), which is activated by Control unit, attachment
(D791-1). The solenoid valve then directs servo pressure to the lock
tongue spool.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.9 ATTACH, menu 9.
"Open lock tongue" solenoid valve, description
The solenoid valve for lock tongue opening controls pressure to the
lock tongue spool so that it opens and pressurises the lock cylinders.

The valve spool is controlled electrically by Solenoid valve, open

lock tongues (Y6039), which is activated by Control unit, attachment
(D791-1). The solenoid valve then directs servo pressure to the lock
tongue spool.

The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.9 ATTACH, menu 9.

Control valve attachment, replacement

See Control valve attachment, replacement, page 7:39.

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7:98 7 Load handling – Lifting hook

7.9.2.3 Pilot-controlled non-return valve for lock

tongue

Pilot-controlled non-return valve for lock tongue,

description
Pilot-controlled non-return valves prevent the uncontrolled opening or
closing of the lock tongues. There is a non-return valve located by
each lock cylinder on the side lift attachment.

009938

Attachment with levelling

7.9.2.4 Lock cylinder

Lock cylinder, description

The lock cylinder activates the lock mechanism so that the lock
tongues are rotated. Two parallel-connected locking cylinders, one in
the right and one in the left spreader beams actuate the lock tongues.
009939

Attachment with levelling

Hydraulic cylinders, repairs

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

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 7 Load handling – Lifting hook 7:99

7.9.2.5 Lock mechanism

Lock mechanism, description

The lock mechanism transfers the force of the lock cylinders to the
lock tongues. Two lock mechanisms, one in the right and one in the
left spreader beam, actuate the lock tongues. The lock mechanism
runs in the corner box.

The lock mechanism consists of a lock cylinder that rotates the lock
tongue, which is fastened to the corner box with a shaft bolt.

7.9.2.6 Lock tongue

Lock tongue, description

WARNING
7
6 Dropped load.
5 Extreme danger!
4 Lock tongues together with lifting hooks hold the load
3 in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
or wear whatsoever.
2
009941

1 The lock tongues secure the load and are located in the corners of
the spreader beam's longitudinal part.
1. Sensor locked lock tongue (B7205LL/RL)
2. Lock tongue The lock tongues are made of high-strength steel.
3. Sensor unlocked lock tongue (B7204L/R) Lock tongues are connected via a linkage system to a hydraulic
4. Alignment pin for sensor alignment lower cylinder which in turn is controlled via a section in the attachment's
container (B7203LL/RL) control valve. Inductive sensors send signals when the lock tongues
5. Lifting hook are locked and unlocked, respectively.

6. Alignment pin for sensor alignment upper

container (B7203LU-2/RU-2)
7. Sensor detection upper container (B7203LU/RU)

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7:100 7 Load handling – Lifting hook

Lock tongue, replacement

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

3 Clean the lock tongues and the area surrounding them.

4 Detach the lock cylinder mounting in the lock tongue.

5 Remove the shaft bolt, which acts like the lock tongue's hinge.
6 Hold the lock tongue while removing the shaft bolt.

2
WARNING
1

009942
Dropped component
1. Lock cylinder mount Risk of pinch injury or product damage.
2. Shaft bolt for lock tongue Lock tongues are heavy.

7 Remove the lock tongue.

8 Fit a new lock tongue. Brush the shaft bolt with Lubricating grease.
9 Fit the shaft bolt with a new lock nut.
10 Fit the screw of the lock cylinder's mounting in the lock tongue.

NOTE
Use a new lock nut and new washers.

Apply lubricating grease to the parts before fitting.

11 Check the positions of the parts and that the lock tongues can
move.
12 Apply lubricating grease to the lock tongue's shaft bolt and the
lock cylinder mounting.
13 Check that the lock tongue mechanism can move.
14 Turn on the main electric power and start the machine.
15 Check that the lock tongues work properly and connect with and
secure the container correctly when lifting.

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 7 Load handling – Lifting hook 7:101

7.9.2.7 Lifting hook

Lifting hook, description

WARNING
7
6 Dropped load.
5 Extreme danger!
4 Lock tongues together with lifting hooks hold the load
3 in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
or wear whatsoever.
2
1 009941
The lifting hooks secure the load and are located in the corners of the
spreader beam's longitudinal part.
1. Sensor locked lock tongue (B7205LL/RL)
2. Lock tongue The lifting hooks are manufactured from high-strength steel in
accordance with international standards. The lifting hooks are marked
3. Sensor unlocked lock tongue (B7204L/R)
with serial numbers.
4. Alignment pin for sensor alignment lower
container (B7203LL/RL)
5. Lifting hook
6. Alignment pin for sensor alignment upper
container (B7203LU-2/RU-2)
7. Sensor detection upper container (B7203LU/RU)

Lifting hook, replacing

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic systems, See section B Safety.

3 Clean the lifting hooks and the area surrounding them.

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7:102 7 Load handling – Lifting hook

4 Remove the lifting hook's shaft bolt.

5 Hold the lifting hook while removing the shaft bolt.

WARNING
Dropped component
1

009948
2 Risk of pinch injury or product damage.
The lifting hook are heavy.
1. Lifting hook
2. Shaft bolt for lifting hook
6 Lift away the lifting hook.
7 Position a new lifting hook in the guide pin.
8 Position the lift pin and guide pin in the spreader beam. Position
the guide pin so that the grease cup is accessible through the
holes in the spreader beam.

NOTE
Use a new lock nut and new washers.

9 Check the positions of the parts and that the lifting hooks can
move.
10 Turn on the main electric power and start the machine.
11 Check that the lifting hooks are working.

7.9.2.8 Alignment and detection sensor

Alignment and detection sensor, description

Two detection sensors (B7203LU/RU) - one at each lifting hook - use
ultrasound to detect distance (and inform the system) if one or two
containers are to be lifted.
1 At each lifting hook, there is one sensor that indicates contact with the
lower container (B7203LL/RL) and one sensor that indicates contact
with the upper container (B7203LU-2/RU-2).
2
The alignment sensors detect the position of a spring pin which is
pressed in when the attachment has contact up against the container.
The sensor is located behind the pin. The position of the sensor can
be adjusted so that it gives a signal when the pin is pressed in and
the head is level with the lower edge of the spreader beam. The
clearance between the attachment and the container's corner boxes
means the sensors stop sending signals when the attachment is lifted.
3 The sensors are supplied power and send a 24 V signal to the
attachment control unit (D791-1) when the indicator pin is pressed in.
4
The signal can be checked via the diagnostic menu. See section 8
009949

Control system, group 8.4.9.7 ATTACH, menu 7.

5

1. Sensor alignment upper container

(B7203LU-2/RU-2)
2. Sensor alignment lower container (B7203LL/RL)
3. Alignment pin upper container
4. Sensor detection upper container (B7203LU/RU)
5. Alignment pin lower container

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 7 Load handling – Lifting hook 7:103

Alignment sensor, checking and adjusting

A 1 Check the sensors for alignment and adjust if necessary. Check
the left and right sides in the same manner.
2 With an unactuated contact pin, the measurement (A) across the
contact pin for the upper container should be approx. 39 mm.
3 When the measurement (A) is reduced to 22 mm, the light (B1) for
contact with the upper container should come on.
B

014724
4 Adjusting:
Secure the contact pin in an appropriate way so that the dimension
B 1 (A) is 22 mm. Now move the sensor along the oval mounting hole
and secure it in exactly the position that it has when the lamp (B1)
A C comes on.

B 2 5 With an unactuated contact pin, the measurement (B) across the

009375

contact pin for the lower container should be approx. 30 mm.

Lights on the side lifting attachment 6 When the measurement (B) is reduced to 18 mm, the light (B2) for
contact with the lower container should come on.
A Green light Lock tongues locked 7 Adjusting:
B1 Orange light Alignment (upper container) Secure the contact pin in an appropriate way so that the dimension
(B) is 18 mm. Now move the sensor along the oval mounting hole
B2 Orange light Alignment (lower container)
and secure it in exactly the position that it has when the lamp (B2)
C Red light Lock tongues released comes on.

Detection sensor, upper container, checking

The sensors for upper container detection use ultrasound to detect
whether one or two containers will be handled. The sensors are
activated when the attachment is 30-50 cm from the container. At that
time, the alignment event menu lights up on the display.
1 Drive the machine toward two containers and check that the
1 alignment event menu lights up on the display no later than when
the attachment is 30 cm from the container.
2 If the event menu for upper container alignment does not light up:
• Use a piece of paper or the like to determine which of the
sensors is not activated.
• Clean the sensor.
• Check the sensor and wiring for damage.
3 Repeat the check from step 1 above. If the alignment event menu
014035

remains unlit, replace the sensor.

1. Detection sensor, upper container

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7:104 7 Load handling – Lifting hook

7.9.2.9 Lock tongue sensor

Lock tongue sensor, description

Lock tongue sensors (B7204L, B7204R, B7205LL and B7205RL)
detect when the lock tongues are locked or unlocked. Four inductive
position sensors, two in each spreader beam, detect the position of
the lock mechanism.

Both sides function in the same way independently of one another. An

1 indicator plate is fitted on the lock tongue by the lock cylinder. When
the lock mechanism is in the position that locks the lock tongues, one
2 of the sensors sends a signal to Control unit, attachment (D791-1).
When the lock mechanism is in the position that unlocks the lock
tongues, the second sensor sends signal to Control unit, attachment
(D791-1). No signals are sent if the lock mechanism stops midway.

The sensors are supplied power by and send a 24 V signal to Control

unit, attachment (D791-1) when the indicator plate is in front of the
009377

3 sensor.

The signal can be checked via the diagnostic menu. See section 8
Right side
Control system, group 8.4.9.8 ATTACH, menu 8.
1. Sensor detection upper container (B7203LU/RU)
2. Sensor unlocked lock tongue (B7204R/L)
3. Sensor locked lock tongue (B7205LL/RL), lower

Lock tongue sensor, checking and adjusting

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

2 Turn the start key to position I and check that the LED on the
"unlocked lock tongues" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 5±1 mm.

3 Check that the "lock tongue open" indicator light is lit.

4 Insert the lifting hooks in the container and lock the lock tongues.

5 Check that the LED on the "locked lock tongues" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 5±1 mm.

6 Check that the indicator light for locked lock tongues is lit.

7 Check that the lock tongues lock correctly. Adjust the lock
cylinders if necessary.

7.9.2.9 Valve block, main pump relief

Valve block, main pump relief, description

See Valve block, main pump relief, description, page 7:46.

7.9.2.10 Pipes and hoses

Piped and hoses, description

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

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7 Load handling – Other functions 7:105

7.10 Other functions

7.10.1 Container counter
Container counter, description

The container counter tracks the number of containers lifted. The

counter has two counters that can be reset separately. For side lift
attachment with lifting hooks, the system detects whether one or two
containers are being handled, and counts up with the corresponding
number.

The container counter uses the alignment sensors and the

twistlock/locked lock tongue sensors to determine when a container is
lifted. The container counter counts lifting when alignment is broken
with locked twistlocks/locked lock tongue and twistlocks/lock tongue
are not opened again within eight seconds.

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7:106 7 Load handling – Container counter

Container counter, function description

Condition Reference value Reference
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage

D1
1, 4, 7
10
D790-1 D795

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

009956
Pos Explanation Signal description Reference
1 The attachment is positioned over - Lifting/lowering, function description, page 7:9
a container with the functions 7.2
Side shift, function description, page 7:36
Lifting/lowering, 7.4 Side shift, 7.5
Spreading and 7.5 Levelling. Spreading, function description, page 7:47
Active levelling, function description, page
7:76
D1: Diagnostic menu, see section 8 Control
system, group 8.4.8.1 ELSERV, menu 1 and
8.4.8.1 ELSERV, menu 2.
2 If the side lifting attachment is Sensor directly opposite Sensor, alignment, description, page 7:88 or
equipped with twistlocks, the left and indicator plate: U = 24 V Alignment and detection sensor, description,
right alignment sensors (B7203L and page 7:102
B7203R) send a voltage signal to the
D2: Diagnostic menu, see section 8 Control
attachment control unit (D791-1).
system, group 8.4.9.7 ATTACH, menu 7
If the side lifting attachment is equipped
with lifting hooks, the left lower,
left upper, right lower and right
upper alignment sensors (B7203LL,
B7203LU-2, B7203RL and B7203RU-2)
send a voltage signal to the attachment
control unit (D791-1).
3 Control unit, attachment (D791-1) sends Checked by control Section 11 Common electrics, group 11.5.3.5
alignment on the CAN bus. system, error shown Attachment control unit (D791-1)
with error code.
4 Twistlocks/Lock tongues are turned to - Twistlocks, function description, page 7:81 or
the locked position and closed with the Lifting hook, function description, page 7:94
function 7.9.1 Twistlocks/7.9.2 Lifting
hook.
5 The sensor for locked twistlocks/lock Sensor directly opposite Sensor, twistlocks, description, page 7:90 or
tongue left (B7205L) and the sensor indicator plate: U = 24 V Lock tongue sensor, description, page 7:104
for locked twistlocks/lock tongue right
D5: Diagnostic menu, see section 8 Control
(B7205R) send a voltage signal to the
system, group 8.4.9.8 ATTACH, menu 8
attachment control unit (D791-1).
6 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits "locked twistlocks/lock system, error shown Attachment control unit (D791-1)
tongues" on the CAN bus. with error code.

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 7 Load handling – Container counter 7:107

Pos Explanation Signal description Reference

7 The container is lifted with the function - Lifting/lowering, function description, page 7:9
7.2 Lifting/lowering.
8 If the side lifting attachment is U=0V Sensor, alignment, description, page 7:88 or
equipped with twistlocks, the left and Alignment and detection sensor, description,
right alignment sensors (B7203L and page 7:102
B7203R) stop sending a voltage signal
D2: Diagnostic menu, see section 8 Control
to the attachment control unit (D791-1).
system, group 8.4.9.7 ATTACH, menu 7
If the side lifting attachment is
equipped with lifting hooks, the left
lower, left upper, right lower and right
upper alignment sensors (B7203LL,
B7203LU-2, B7203RL and B7203RU-2)
stop sending a voltage signal to the
attachment control unit (D791-1).
9 Control unit, attachment (D791-1) sends Checked by control Section 11 Common electrics, group 11.5.3.5
no alignment on the CAN bus. system, error shown Attachment control unit (D791-1)
with error code.
10 If the twistlocks/lock tongue remains - Section 11 Common electrics, group 11.5.3.1
locked for 8 seconds, the cab control unit Cab control unit (D790-1)
(D790-1) adds one lift to the container
counter.

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7:108

VDCF05.01GB Workshop Manual DCF 80-100

 8:1

8 Control system

Contents 8 Control system

8 Control system ...................................................................................................8:3
8.1 Controls and instruments .................................................................................8:4
8.1.10 Error code menu .........................................................................................8:4
8.2 Monitoring ........................................................................................................8:7
8.2.1 Overload system .........................................................................................8:7
8.2.2 Bypass ........................................................................................................8:7
8.2.3 Speed limitation...........................................................................................8:7
8.2.4 Service indicator..........................................................................................8:8
8.2.6 Height limitation...........................................................................................8:8
8.2.7 Height warning ............................................................................................8:8
8.4 Diagnostics ......................................................................................................8:9
8.4.1 CAN/POWER ............................................................................................ 8:11
8.4.2 LIGHTS .....................................................................................................8:24
8.4.3 CAB ...........................................................................................................8:34
8.4.4 CLIMATE ...................................................................................................8:40
8.4.5 HYD...........................................................................................................8:46
8.4.6 ENGINE ....................................................................................................8:51
8.4.7 TRANSM ...................................................................................................8:57
8.4.8 ELSERV ....................................................................................................8:68
8.4.9 ATTACH, lifting hook attachment ..............................................................8:72
8.4.9 ATTACH, twistlock attachment ..................................................................8:87
8.4.10 OLS .........................................................................................................8:100
8.4.11 EXTRA ....................................................................................................8:102
8.5 Setup............................................................................................................ 8:115
8.5.1 Initiation ................................................................................................... 8:115
8.5.2 Calibration ...............................................................................................8:136

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8:2

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8 Control system – Control system 8:3

8 Control system
Control system, general
In many cases, the machine's functions are controlled electrically. The
signals that control the machine are monitored to warn the operator
or limit the machine's functions in the event of certain dangerous
situations or if there are malfunctions in the machine.

The control system function is divided into the following functions:

• Monitoring
• Error codes
• Diagnostics
• Setup
• Software

Monitoring functions describe the machine's monitoring functions that

warn the operator or limit the machine's functions in the event of any
dangerous situations.

Error codes notify operators and mechanics when malfunctions have

been detected.

Diagnostic test is tool for performing service and troubleshooting with

menus in the machine's display.

Settings is the tool for setting and adapting the machine's functions.

The software creates the functions in the control system.

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8:4 8 Control system – Controls and instruments

8.1 Controls and instruments

8.1.10 Error code menu
Error code menu, description
The control and monitoring system's display is divided into four fields
C where the information is shown (see figure to the left).
• Field B: Error code level is shown with a symbol.
D E
• Field C: Shows error code.
B • Field D: Shows type of error.

000389
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator's
manual.
Field B: Error code level
Field B: Error code level
C
The control and monitoring system gives error code information in
D E three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
• Stop
000350

Indicates a serious malfunction that may jeopardise the operator's

safety or cause machine failure. The error code must be attended
to immediately. Stop working with the machine and contact
service immediately.
The error code is shown automatically on the display.
• Warning
C Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
D E contact service as soon as possible.
The error code is shown automatically on the display.
000351

• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to
D E fix the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
menu for service.
000352

Field C: Error code number

Field C: Error code number
C
The control and monitoring system gives error codes from three
D E sub-systems:
• Machine:
B
000389

Shown with error code number XXX on display.

• Engine:
X X X /Y Y Shown with error code number XXX/YY on display.

D NOTE
B If several error codes come from the engine, the error code level
013390

is shown for the most serious error code.

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 8 Control system – Error code menu 8:5

• Transmission:
X X /Y Y Shown with error code number XX/YY on display.

013391
Field D: Type of error
Field D: Type of error
1 2 3
1. Temperature too high/too low.
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6
5. Incorrect signal from control.
6. Incorrect signal from battery.
7. Incorrect signal from spool.
8. Level too high/low
7 8 9
9. Incorrect signal to bulb.
10. Incorrect signal, for example, open circuit.
11. Incorrect signal to engine.

10 11
002058

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8:6 8 Control system – Error code menu

Field E: Affected function

Field E: Affected function
1 2 3
1. Attachment
2. Rotation of attachment
3. Side shift, attachment
4 5 6 4. Length adjustment attachment
5. Levelling attachment
6. Twistlocks
7. Forks up/down
7 8 9 8. Tilt forks
9. Side shift forks
10. Spreading forks
11. Rotation forks
10 11 12
12. Overload protection
13. Hydraulic functions
14. Brake system
13 14 15 15. Steering
16. Engine
17. Transmission
18. Central lubrication
16 17 18 19. Control unit
20. Hardware-related error
21. Cab
22. Air conditioning
19 20 21 23. Fuel system
24. Headlights
25. Windscreen wipers
22 23 24 26. Battery voltage
27. Bulb for lighting

25 26 27
010153

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8 Control system – Monitoring 8:7

8.2 Monitoring
8.2.1 Overload system
Overload system, function description
Not used.

8.2.2 Bypass
Bypass, description
Bypassing is activated with the bypass switch.

By-passing the safety system allows:

• locking and opening of twistlocks without complete alignment
• 20'-40' spreading with locked twistlocks
• lowering a load with alignment on top lift
• manual control of the recirculation damper for ECC or EHC
• release of parking brake in the event of parking brake switch
malfunction
• output signal to solenoid valves with active error codes
• engagement of a gear without the operator in the operator's seat,
the machine can only move at reduced speed

DANGER
Bypassing the safety systems results in a risk of
tipping. Use at your own risk.
Extreme hazard to personal health and risk of property
damage!
Only use the bypass of safety systems in emergency
situations.

8.2.3 Speed limitation

Speed limitation, description
Speed limitation prevents the machine's speed from exceeding the
preset value by limiting gear position and engine speed.

Machine speed is limited when:

• the emergency stop switch is activated.
• the cab is tilted.
• load not in transport position during transport. Maximum speed
is 5 km/h.
• constant speed limitation is set .
• Hydraulic oil temperature too high.

Speed limitation is set via the initiation menu, see section 8 Control
system, group 8.5.1.4 INIT DRIVE-TRAIN, menu 9.

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8:8 8 Control system – Service indicator

8.2.4 Service indicator

Service indicator, resetting

1 Machine in service position, see section B Safety.

2 Navigate first to the service menu and press Enter.

000056
3 Enter the code to reset the service indicator.
Code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060

The code determines which service menu is activated (Service,

Diagnostic test, Initiation or Calibration).

4 Reset the service indicator by pressing Enter. NEXT SERVICE is

SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh To change duration of the service interval, set the desired interval
SERVICE INTERVALL with the plus or minus key.
STORED XXXXh
004908

PRESENT XXXXh

8.2.6 Height limitation

Height limitation, description

Height limitation is part of the control system and prevents the machine
lifting higher than a preset height without the driver being informed.

Height limitation is controlled by the control system with signals from

Mast position sensor. When the Mast position sensor indicates that the
permitted height has been reached the lift is blocked and the display
height restriction information is also activated.

For details about lifting and lowering, see section 7 Load handling,
group 7.2 Lifting/lowering.

The height limitation values can be checked via the diagnostic menu.
see 8 Control system, group 8.4.10.3 OLS, menu 3.

8.2.7 Height warning

Height warning, description

Height warning warns when the set maximum lift height is reached.
The height warning is adjustable according to the customer's needs.

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 8 Control system – Diagnostics 8:9

8.4 Diagnostics
Diagnostic test, general
The machine has built-in functions for troubleshooting called
DIAGNOSIS diagnostic test. The diagnostic test consists of several menus shown
CAN/POWER LIGHTS CAB on the display. The menus are grouped for faster access. The
CLIMATE HYD ENGINE following pages describe the content of the menu figures and which
TRANSM ELSERV ATTACH functions can be controlled.

005263
OLS EXTRA
The diagnostic test is divided into the following groups:

• Voltage feed and communication for the Control system,

CAN/POWER, description, page 8:11.
• Lighting, LIGHTS, description, page 8:24.
• Cab functions, CAB, description, page 8:34.
• Air conditioning, CLIMATE, description, page 8:40.
• Hydraulic functions, HYD, description, page 8:46.
• Engine, ENGINE, description, page 8:51.
• Transmission, TRANSM, description, page 8:57.
• Functions for electric servo, ELSERV, description, page 8:68.
• Attachment functions, ATTACH, description, page 8:72.
• Overload protection, OLS, description, page 8:100.
• Optional functions, EXTRA, description, page 8:102
– Mini-wheel or lever steering, EL-STEERING, menu 1, page
8:102.
– Tiltable cab, MOVE-CAB, menu 1, page 8:106.
– RMI, RMI, menu 1, page 8:112.

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8:10 8 Control system – Diagnostics

Diagnostic menu, description

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

7 DIAG CAB 2(X)

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

008873
FEEDBACK 0

1. DIAG = Diagnostic menus

2. Menu group
3. Menu number
4. Total number of menus in the loop. The number
of menus depends on the equipment fitted to the
machine. For this reason, number of menus is
indicated with (X) in this manual.
5. Signal value
6. Variable
7. Menu heading

DIAG Indicates that diagnostic tests are selected.

CAB Indicates which menu group is selected, these groups are:
CAN/POWER, description, page 8:11.
LIGHTS, description, page 8:24.
CAB, description, page 8:34.
CLIMATE, description, page 8:40.
HYD, description, page 8:46.
ENGINE, description, page 8:51.
TRANSM, description, page 8:57.
ELSERV, description, page 8:68.
ATTACH, description, page 8:72.
OLS, description, page 8:100.
EXTRA, description, page 8:102.
2 Number of current menu. Every menu group consists of several menus in a loop.
(X) Total number of menus in the group. The number of menus depends on the equipment fitted to the
machine. For this reason, number of menus is indicated with (X) in this manual.
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g., a switch.
OUTPUT: a digital output signal, e.g., feed to a motor.
INPUT: an analogue input signal, e.g., from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.

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 8 Control system – CAN/POWER 8:11

Signal value Measurement value or status for the signal for variable. On the same row there are different types
that are interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.

8.4.1 CAN/POWER
CAN/POWER, description
This group handles redundant voltage feed to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selections with function key for Enter.
TRANSM ELSERV ATTACH
005263

OLS EXTRA

8.4.1.1 CAN/POWER, menu 1

PRESENT REDCAN STATUS, COMMUNICATION

MODE
Description: Indicates communication status for the redundant CAN
DIAG CAN/POWER 1(X) bus.
PRESENT REDCAN STATUS
COMMUNICATION MODE X Circuit diagram: 11.6-1
NUMBERS OF UNITS X Contact: -
005266

SEGMENT ERROR X
Function: 11.6.2 Redundant CAN bus

Signal value:

3 OK.
2 Segment check
0 Error.

PRESENT REDCAN STATUS, NUMBER OF UNITS

Description: Indicates the number of control units, excluding Cab
control unit (D790-1) which should be on the current machine. The
number is dependent on the installed options.

Circuit diagram: Circuit 11.6-1

Contact: -

Function: 11.6.2 Redundant CAN bus

Signal value:

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

nodes depends on installed options.

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8:12 8 Control system – CAN/POWER

PRESENT REDCAN STATUS, SEGMENT ERROR

Description: Indicates if there is open circuit on the redundant CAN bus
and if there is, where the first open circuit is. If there is open circuit, it is
indicated with a number that corresponds to the defective segment on
the redundant CAN bus.

Circuit diagram: Circuit 11.6-1

Contact: -

Function: 11.6.2 Redundant CAN bus

Signal value:

0 No open circuits.
>0 If X is separated from 0, the first segment is indicated
as missing contact. A 1 means that the first segment is
defective, that is, that contact between first and second
control unit is cut off.
To see which control units are installed on the
machine along with their order, use diagnostic menu
CAN/POWER, menu 2, see PRESENT REDCAN
STATUS, CONNECTED CITIES, page 8:12.

8.4.1.2 CAN/POWER, menu 2

PRESENT REDCAN STATUS, CONNECTED CITIES

Description: Indicates which control units have contact with Control
DIAG CAN/POWER 2(X) unit, cab (D790-1) via the redundant CAN bus. Note that certain
PRESENT REDCAN STATUS control units are optional and may not be installed on the machine.
CONNECTED CITIES
D797-1 D797-2 XX Circuit diagram: 11.6-1, 11.6-2B, 11.6-2C
005267

D795 D791-1 XX Contact:

D795: K1:10, K1:11, K1:12 and K1:13
D797-1, D797-2, D791-1: K2:2, K2:3, K2:4 and K2:5

Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.3 Frame control

unit (D797-2), 11.5.3.5 Attachment control unit (D791), 11.5.3.12 KID
control unit (D795), 11.6.2 Redundant CAN bus.

Signal value:

1 Communication with the node is OK.

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

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 8 Control system – CAN/POWER 8:13

8.4.1.3 CAN/POWER, menu 3

PRESENT OPTION KDU

Description: Indicates which optional control units should be present
DIAG CAN/POWER 3(X) on the machine and if they have working communication with the
PRESENT OPTION KDU cab KCU control unit (D790-1).

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

007183
KDU D791-1 XY Contact: -

Function: 11.6.2 Redundant CAN bus

Signal value:

00 The control unit is not installed on the machine.

10 The control unit is installed on the machine but there is no
communication with the cab control unit (D790-1).
11 The control unit is installed on the machine and there is
communication with the cab control unit (D790-1).

8.4.1.4 CAN/POWER, menu 4

PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE

Description: Indicates status for engine in the drive-train's CAN bus.
DIAG CAN/POWER 4(X)
PRESENT DRIVE-TRAIN Circuit diagram: Engine circuit group 1.0, CAN bus circuit group 11.6
CAN BUS STATUS Contact:
ENGINE X
005269

TRANSMISSION X CAN J1939 from D790-1/K13:1 and K13:2 to D794/1 and 2

Function: 11.6.3 CAN bus drive-train

Signal value:

1 Communication with the node is OK.

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

NOTE
The cable harness for CAN bus drive-train is common to the
engine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off, start
troubleshooting at the cable harness between the cab electronic
box and the frame electronic box. If there is communication (either
engine or transmission), this rules out a fault in the cable harness
between the cab electronic box and the frame electronic box.

PRESENT DRIVE-TRAIN CAN BUS STATUS,

TRANSMISSION
Description: Indicates status for transmission in the drive-train's CAN
bus.

Circuit diagram: Transmission circuit group 2.0, CAN bus circuit group
11.6

Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2

and M2

Function: 11.6.3 CAN bus drive-train

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8:14 8 Control system – CAN/POWER

Signal value:

1 Communication with the node is OK.

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

NOTE
The cable harness for CAN bus drive-train is common to the
engine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off, start
troubleshooting at the cable harness between the cab electronic
box and the frame electronic box. If there is communication (either
engine or transmission), this rules out a fault in the cable harness
between the cab electronic box and the frame electronic box.

8.4.1.5 CAN/POWER, menu 5

IGNITION, KEY IN
Description: Indicates if ignition is switched on (key in ignition key
DIAG CAN/POWER 5(X) lock).
IGNITION
KEY IN X Circuit diagram: Circuit 11.5-3
RELAY K315-1 XY Connection: signal from S150/15 to digital in D790-1/K11:1
007126

RELAY K315-2 XY
Function: 11.5.1.3 Ignition voltage

Signal value:

1 Input signal active.

0 No signal.

IGNITION, RELAY K315-1

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

Circuit diagram: Circuit 11.5-3

Connection: output signal from D790-1/K10:10 to K315-1

Function: 11.5.1.3 Ignition voltage (15)

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

IGNITION, RELAY K315-2

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

Circuit diagram: Circuit 11.5-3

Connection: output signal from D790-1/K10:16 to K315-2

Function: 11.5.1.3 Ignition voltage (15)

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 8 Control system – CAN/POWER 8:15

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.1.6 CAN/POWER, menu 6

EMERGENCY STOP, SW
Description: Indicates if switch, emergency stop switch, is activated.
DIAG CAN/POWER 6(X)
EMERGENCY STOP, SW X Circuit diagram: sheet 11.5-6
RELAY K3009-1 XY Connection: signal from S250/2 to digital in D790-1/K8:4
FEEDBACK X
007127

RELAY K3009-2 XY Function: 11.5.1.4 Emergency stop switch voltage (15E)

Signal value:

1 Input signal active.

0 No signal.

EMERGENCY STOP, RELAY K3009-1

Description: Status for control current to relay K3009-1, for emergency
stop switch voltage, 15E voltage.
Circuit diagram: sheet 11.5-6
Connection: signal from D790-1/K10:11 to K3009-1/86
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

EMERGENCY STOP, FEEDBACK

Description: Feedback signal from emergency stop switch voltage
relay (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 Emergency stop switch voltage (15E)
Signal value:

1 Input signal active.

0 No signal.

EMERGENCY STOP, RELAY K3009-2

Description: Status of control current to emergency stop switch voltage
relay (K3009-2), 15E-voltage.

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8:16 8 Control system – CAN/POWER

Circuit diagram: sheet 11.5-6

Connection: signal from D790-1/K10:12 to K3009-2/86

Function: 11.5.1.4 Emergency stop switch voltage (15E)

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.1.7 CAN/POWER, menu 7

790-1 CAB, POWER

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

Function: 11.5.1 Voltage feed

Signal value: XX.XXV = voltage on the connection. The signal value

should be 22-30 V (battery voltage).

790-1 CAB, 5V REF

Description: Reference voltage 5 V to controls in cab.

Circuit diagram: Circuits 9.4-1, 9.4-2 and 9.3-3 (contact 1, 2), Circuit
1.0-1 (contact 3), Circuit 7.0-1 (contact 4), Circuit 5.2-1 (contact 5)

Contact:
1. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10
2. signal from digital out D790-1/K5:11 to S118/1, S139/1 and S117/1
3. signal from digital out D790-1/K5:13 till B690-1/1 and B690-2/1
4. signal from digital out D790-1/K7:2 to R8071/1, R8072/1, R8073/1,
R8074/1, R8075-1/1 and R8075-2/1
5. signal from digital out D790-1/K9:7 to R825-1/1 and R825-2/1

Function: 9.4 Heating, ventilation and air conditioning (contact 1 and

2); 1 Engine and 2 Transmission (contact 3); 7 Load handling (contact
4); 5 Steering (contact 5)

Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).

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 8 Control system – CAN/POWER 8:17

8.4.1.8 CAN/POWER, menu 8

790-1 CAB, 24V SENSOR SUPPLY

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

005275
3. -
4. -
5. Circuits 4.0-1, 7.5-1, 7.9-1, 8.2-1, 9.1-1, 9.3-3, 9.10-1 and 11.5-6
6. Circuit 5-2_1
7. -
8. Circuit 9.7-1
9. Circuit 9.5-1
10. Circuit 9.5-1

Contact:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S100/5, S110/5, S105-1/5,
S105-2/5, S105-3/5, S143/5, S199-1/5, S199-3/5, S199-4/5,
S220-1/1
3. signal from digital out D790-1/K6:13 not connected
4. signal from digital out D790-1/K7:12 not connected
5. signal from digital out D790-1/K8:16 to S107/5, S169/3, S199-2/5,
S250/1, S1002/2, S1003/3, S1004/5, S1005/5, S1010/3, S1012/3,
S1037/5
6. signal from digital out D790-1/K9:1 to S113/5, S149-2/5, S160-2/3
7. signal from digital out D790-1/K10:1 not connected
8. signal from digital out D790-1/K11:12 to S230/2
9. signal from digital out D790-1/K12:1 to M650-2/53a
10. signal from digital out D790-1/K12:3 to M650-3/53a

Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. -
4. -
5. 11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake
system; 8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab;
7.5 Spreading; 7.8 Levelling; 7.9.1 Twistlocks
6. 5 Steering
7. -
8. 9.3.14 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof

Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK or open circuit.

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8:18 8 Control system – CAN/POWER

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

Description: Voltage feed when engine speed is higher than 500 rpm.

Circuit diagram: Circuit 9.1-2

Connection: signal from digital out D790-1/K10:9 to P708/+ and

K358/86

Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.1.9 CAN/POWER, menu 9

795 DISPLAY, RED. POWER

Description: Redundant voltage to Control unit KID (D795).
DIAG CAN/POWER 9(X)
795 DISPLAY Circuit diagram: Circuit 11.6-1

Contact:
RED.POWER LE X RI X
005276

Le: redundant feed to D790/K1:8

Ri: redundant feed to D790/K1:7

Function: 11.5.1.2 Redundant voltage feed of control units

Signal value:

1 Feed active.
0 No feed.

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 8 Control system – CAN/POWER 8:19

8.4.1.10 CAN/POWER, menu 10

797-1 FRAME, POWER

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

005277
POWER 2 X
Function: 11.5.1.3 Ignition voltage (15)

Signal value: XX.XXV = voltage on connection. The signal value

should be 22-30 V (battery voltage).

797-1 FRAME, RED. POWER

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

Circuit diagram: Circuit 11.6-1

Contact:
• Le: redundant feed to D797-1/K2:7
• Ri: redundant feed to D797-1/K2:8

Function: 11.5.1.2 Redundant voltage feed of control units

Signal value:

1 Feed active.
0 No feed.

797-1 FRAME, POWER 2

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

Circuit diagram: Circuit 11.5-4

Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/1 to

D797-1/K2:11

Function: 11.5.1.3 Ignition voltage (15)

Signal value:

1 Feed active.
0 No feed.

8.4.1.11 CAN/POWER, menu 11

797-1 FRAME, 5V REF

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

Function: 7.2.8 Hydraulic pressure sensor, lift cylinder and 7.7.8

Hydraulic pressure sensor, tilt cylinder

Signal value: X.XXV = 5.00 V. Important that signal value is stable

(not varying).

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8:20 8 Control system – CAN/POWER

8.4.1.12 CAN/POWER, menu 12

793 TRANSMISSION, POWER

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

005279
SENSOR SUPPLY XX.XXV Function: 11.5.1.1 Battery voltage (30)

Signal value: XX.XXV = voltage on the connection. The signal value

should be 22-30 V (battery voltage).

793 TRANSMISSION, IGNITION POWER

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

Circuit diagram: Circuit 2.0-2A1

Connection: 15-voltage from K315/87 via F54/4 and F58-2/6 to

D793/S2

Function: 11.5.1.3 Ignition voltage (15)

Signal value: XX.XXV = voltage on the connection. The signal value

should be 22-30 V (battery voltage).

793 TRANSMISSION, SENSOR SUPPLY

Description: Voltage feed to sensors on the transmission, reference
voltage of 5 V.

Circuit diagram: Circuits 2.0-2A2, 2.0-2A3

Connection: 5V analogue Ref from D793/M1 to S221/1

Function: 2.8 Control system, transmission

Signal value: XX.XXV = voltage on the connection. The signal value

should be 8 V, stable (not varying).

8.4.1.13 CAN/POWER, menu 13

797-2 FRAME (OPT), POWER

DIAG CAN/POWER 13(X)

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

EME STOP POWER X Circuit diagram: Circuit 11.5-5

Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/3 to

D797-2/K2:1, D797-2/K2:9 and D797-2/K2:10

Function: 11.5.1.3 Ignition voltage (15)

Signal value: XX.XXV = voltage on the connection. The signal value

should be 22-30 V (battery voltage).

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 8 Control system – CAN/POWER 8:21

797-2 FRAME (OPT), RED. POWER

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

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

1 Feed active.
0 No feed.

797-2 FRAME (OPT), EME STOP POWER

Description: Emergency stop switch voltage to the frame control unit

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

1 Feed active.
0 No feed.

8.4.1.14 CAN/POWER, menu 14

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

DIAG CAN/POWER 14(17)

797-2 FRAME (OPT) Description: Voltage feed 24 V to sensors connected to the frame
24V SENSOR SUPPLY XY control unit, option (D797-2).
5V REF X.XXV
005281

Circuit diagram: Circuit 9.3-3

Connection: signal from digital out D797-2/K1:7 to S720-F/2 and

S720-R/2.

Function: 9.3.9 Sensor, reversible driver's seat

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

797-2 FRAME (OPT), 5V REF

Not used.

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8:22 8 Control system – CAN/POWER

8.4.1.15 CAN/POWER, menu 15

791-1 ATTACHMENT, EME POWER

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

005282
EME POWER 2 X
Function: 11.5.1.4 Emergency stop switch voltage (15E)

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

791-1 ATTACHMENT, RED. POWER

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

Circuit diagram: Circuit 11.5-1, 11.5-6, 11.6-1, 11.6-2B, 11.6-2C

Contact:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8

Function: 11.5.1.2 Redundant voltage feed of control units

Signal value:

1 Feed active.
0 No feed.

791-1 FRAME, EME POWER 2

Description: Emergency stop switch voltage (15E) to attachment
control unit (D791-1).

Circuit diagram: Circuit 11.5-5

Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1

to D791-1/K2:11

Function: 11.5.1.4 Emergency stop switch voltage (15E)

Signal value:

1 Feed active.
0 No feed.

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 8 Control system – CAN/POWER 8:23

8.4.1.16 CAN/POWER, menu 16

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

Description: Voltage feed to sensors connected to the attachment
DIAG CAN/POWER 16(X) control unit (D791-1).
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY Circuit diagram: Circuit 7.5-2, 7.9-2
5V REF X.XXV Twistlock attachment

005283
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R

Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position

sensor, 7.9.1.8 Twistlocks sensor

Lifting hook

Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,

B777R, B7203LU-2, B7203RU-2, B7203LL, B7203RL, B7203LU,
B7203RU, B7204L, B7204R, B7205LL and B7205RL

Function: 7.5.6 Spreading position sensor, 7.9.2.8 Alignment and

detection sensor, 7.9.2.9 Lock tongue sensor

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

791-1 ATTACHMENT (OPT), 5V REF

Not used.

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8:24 8 Control system – LIGHTS

8.4.1.17 CAN/POWER, menu 17

REDCAN STATUS CHECK

Description: Control function from the redundant CAN bus. Cab
DIAG CAN/POWER 17(X) control unit (D790-1) performs a segment check to verify that all
REDCAN STATUS CHECK control units are in contact and are connected in the correct order.
PRESS ENTER The control system indicates the fault by numbering the cables
between the control units (segments) from 1 onwards. Segment 1 is

005284
SEGMENT ERROR X always between cab control unit (D790 -1) and the next Control unit.
The last segment is always between Control unit KID (D795) and
Control unit, cab (D790-1). The segments in between vary depending
on machine configuration.
Circuit diagram: Circuit CAN bus group 11.6
D790-1 D791 D797-2 D797-1
CAN L CAN R CAN L CAN R CAN L CAN R CAN L CAN R Contact: -
1 2 3
Function: 11.6.2 Redundant CAN bus
5 4
CAN R CAN L
Signal value:
008878

D795
0 No errors.
Segment numbering with maximum number of control >0 X > 0, digit denotes incorrect segment. Use the circuit
units. Control units marked with dashes are optional. diagram to find the defective segment.

8.4.2 LIGHTS
LIGHTS, description
This group covers lighting.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005285

OLS EXTRA

8.4.2.1 LIGHTS, menu 1

MAIN LIGHT, SWITCH

Description: Signal from headlights switch.
DIAG LIGHTS 1(X)
MAIN LIGHT Circuit diagram: Circuit 9.6-4
SWITCH X Connection: signal from S100/1 to digital in D790-1/K6:5
005286

Function: 9.6.1 Headlights.

Signal value:

1 Input signal active.

0 No signal.

8.4.2.2 LIGHTS, menu 2

PRESENT OUTPUT SIGNAL, SIDE LIGHTS

Description: Voltage feed to side running lights.
DIAG LIGHTS 2(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuits 9.6-5 and 9.6-6

Connection: digital out from D797-1/K1:2 to H416-1, H416-2, H417-1

SIDE LIGHTS XY and H417-2
005287

REAR LIGHTS XY
Function: 9.6.2 Running lights

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 8 Control system – LIGHTS 8:25

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

PRESENT OUTPUT SIGNAL, REAR LIGHTS

Description: Voltage feed to tail lights.

Circuit diagram: Circuit 9.6-6

Connection: digital out from D797-1/K1:33 to H412L and H412R

Function: 9.6.3 Tail lights

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.2.3 LIGHTS, menu 3

HEAD LIGHTS, SWITCH
Description: Lighting headlights front, switch.
DIAG LIGHTS 3(X)
HEAD LIGHTS Circuit diagram: Circuit 9.6-4
SWITCH X Connection: from S162:56A to digital in D790-2/K3:9
HEAD LE/RI XY
005288

DIMMED LE/RI XY Function: 9.6.1 Headlights

Signal value:

1 Input signal active.

0 No signal.

HEADLIGHTS, HEAD LE/RI

Description: Voltage feed to headlights, high beam.

Circuit diagram: Circuit 9.6-5

Connection: digital out from D797-1/K1:15 to E402L-1 and E402R-1

Function: 9.6.1 Headlights

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

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8:26 8 Control system – LIGHTS

HEADLIGHTS, DIMMED LE/RI

Description: Voltage feed to headlights, low beam.

Circuit diagram: Circuit 9.6-5

Connection: digital out from D797-1/K1:28 to E400L and E400R

Function: 9.6.1 Headlights

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.2.4 LIGHTS, menu 4

PRESENT INPUT SIGNAL, HAZARD SWITCH
Description: Signal from switch, flashing hazard lights (Hazard).
DIAG LIGHTS 4(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit 9.6-7
HAZARD SWITCH X Connection: signal from S109/1 to digital in D790-1/K5:6
FLASH.SW. LE X RI X
005289

Function: 9.7 Signalling system

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, FLASH.SW.

Description: Signal from switch, direction indicators.

Circuit diagram: Circuit 9.6-7

Contact:
• LE: signal from S161/6 to digital in D790-2/K8:8
• RI: signal from S161/1 to digital in D790-2/K8:9

Function: 9.6 Lighting system

Signal value:

1 Input signal active.

0 No signal.

8.4.2.5 LIGHTS, menu 5

PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT
F/R
Description: Voltage feed to direction indicator, left-hand side.
DIAG LIGHTS 5(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit 9.6-7
HAZARD/FLASHER Connection: digital out from D797-1/K1:30 to H422 and H426
LEFT F/R XY
005290

RIGHT F/R XY Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)

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 8 Control system – LIGHTS 8:27

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

PRESENT OUTPUT SIGNAL HAZARD/FLASHER,

RIGHT F/R
Description: Voltage feed to direction indicator, right-hand side.

Circuit diagram: Circuit 9.6-7

Connection: digital out from D797-1/K1:31 to H423 and H427

Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights

(Hazard)

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.2.6 LIGHTS, menu 6

ROTATION BEACON, SWITCH

Description: Signal from switch, revolving beacon.
DIAG LIGHTS 6(X)
ROTATION BEACON Circuit diagram: Circuit 9.6-4
SWITCH X Connection: from S110/1 to digital in D790-1/K6:4
OUTPUT XY
005291

Function: 9.6.8 Revolving beacon

Signal value:

1 Input signal active.

0 No signal.

ROTATION BEACON, OUTPUT

Description: Voltage feed to revolving beacon.

Circuit diagram: Circuit 9.6-4

Connection: digital out from D790-1/K2:5 to H428

Function: 9.6.8 Revolving beacon

Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

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8:28 8 Control system – LIGHTS

8.4.2.7 LIGHTS, menu 7

PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH
Description: Signal from make-contact (closing switch) brake lights.
DIAG LIGHTS 7(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit 9.6-5
BRAKE LGT SWITCH X Connection: from S216/2 to digital in D797-1/K1:20
REVERSE LGT SIGNAL X

005292
Function: 4.3.8 Make-contact (closing switch) brake lights

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL

Description: Signal from Control unit, transmission (D793) when
reverse gear is activated.
Circuit diagram: Circuit Lighting group 9.6
Contact: -
Function: 9.6.5 Back-up lights
Signal value:

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

Control unit, transmission (D793).
0 No signal.

8.4.2.8 LIGHTS, menu 8

PRESENT OUTPUT SIGNAL, BRAKE LGT
Description: Voltage feed to brake lights.
DIAG LIGHTS 8(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit 9.6-6
BRAKE LGT LE XY RI XY Contact:
REV. LGT LE XY RI XY
005293

REVERSE ALARM XY • LE: digital out from D797-1/K1:7 to H411L

• RI: digital out from D797-1/K1:9 to H411R

Function: 9.6.4 Brake lights

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

PRESENT OUTPUT SIGNAL, REV LGT

Description: Voltage feed to back-up lights.
Circuit diagram: Circuit 9.6-6
Contact:
• LE: digital out from D790-1/K2:6 to E405L
• RI: digital out from D790-1/K2:7 to E405R
Function: 9.6.5 Back-up lights

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 8 Control system – LIGHTS 8:29

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

PRESENT OUTPUT SIGNAL, REVERSE ALARM

Description: Voltage feed to reverse alarm.

Circuit diagram: Circuit 9.7-2

Connection: digital out from D797-1/K1:10 to H965

Function: 9.7.5 Reverse alarm

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.2.9 LIGHTS, menu 9

CAB LIGHT, MANUAL SWITCH

Description: Signal from switch, lighting cab.
DIAG LIGHTS 9(X)
CAB LIGHT Circuit diagram: Circuit 9.6-8
MANUAL SWITCH X Connection: signal from D790-2/K8:11 to digital in D790-1/K11:2
DOOR SWITCH X
005294

OUTPUT XXX Function: 9.6 Lighting system

Signal value:

1 Input signal active.

0 No signal.

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8:30 8 Control system – LIGHTS

CAB LIGHT, DOOR SWITCH

Description: Signal from break contact (opening switch) door.

Circuit diagram: Circuit 9.6-8

Connection: signal from S266-LE or S266-RI (connected in parallel)

to digital in D790-1/K11:3

Function: 9.10.2 Doors

Signal value:

1 Input signal active.

0 No signal.

CAB LIGHT, OUTPUT

Description: Voltage feed to interior lighting 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

corresponds to battery voltage).

8.4.2.10 LIGHTS, menu 10

WORKING LIGHT MAST, SWITCH

Description: Signal from switch for working light, mast.
DIAG LIGHTS 10(X)
WORKING LIGHT MAST Circuit diagram: Circuit 9.6-3
SWITCH X Connection: signal from S105-3/1 to digital in D790-1/K6:3
OUTPUT LE/RI XY
005295

Function: 9.6 Lighting system

Signal value:

1 Input signal active.

0 No signal.

WORKING LIGHT MAST, OUTPUT

Description: Voltage feed to working light, mast.

Circuit diagram: Circuit 9.6-3

Connection: digital out from D797-1/K1:1 to E404L-1 and E404R-1

Function: 9.6.9 Working light, mast

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

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 8 Control system – LIGHTS 8:31

8.4.2.11 LIGHTS, menu 11

WORKING LIGHT EXTRA OUTPUT, D797-1 C1 P42

Description: Voltage feed to auxiliary working light.
DIAG LIGHTS 11(X)
WORKING LIGHT EXTRA Circuit diagram: Circuit 9.6-9
OUTPUT Connection: digital out from D797-1/K1:42 to E404L-4 and E404R-4
D797-1 C1 P42 XY

005296
D797-2 C1 P42 XY Function: 9.1.4 Switch for working light, front wing, 9.1.5 Switch for
working light, attachment, 9.1.6 Switch for working light, mast

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42

Description: Voltage feed to auxiliary working light.

Circuit diagram: Circuit 9.6-10

Connection: digital out from D797-2/K1:42 to E404L-2 and E404R-2

Function: 9.6.9 Working light, mast, 9.6.10 Working light, cab, 9.6.12
Working light, attachment, 9.6.14 Working light, front wing

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.2.12 LIGHTS, menu 12

WORKING LIGHT CAB, SWITCH

Description: Signal from switch, working lights cab roof.
DIAG LIGHTS 12(X)
WORKING LIGHT CAB Circuit diagram: 9.6-1
SWITCH X Connection: signal from S105-1/1 to digital in D790-1/K6:10
005297

OUTPUT 20' XY 40' XY Function: 9.6 Lighting system

Signal value:

1 Input signal active.

0 No signal.

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8:32 8 Control system – LIGHTS

WORKING LIGHT CAB, OUTPUT

Description: Voltage feed to working lights cab roof.

Circuit diagram: 9.6-1

Contact:
• 20': digital out from D790-1/K7:8 to E406L-2 and E406R-2
• 40': digital out from D790-1/K10:8 to E406L-1 and E406R-1

Function: 9.6.10 Work light cab

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-circuiting
can only be detected when the output signal is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.2.13 LIGHTS, menu 13

WORKING LIGHT ATTACH, SWITCH

Description: Signal from switch, working lights attachment.
DIAG LIGHTS 13(X)
WORKING LIGHT ATTACH Circuit diagram: 9.6-2
SWITCH X Connection: signal from S105-2/1 to digital in D790-1/K6:2
OUTPUT LE XY RI XY
008895

Function: 9.6 Lighting system

Signal value:

1 Input signal active.

0 No signal.

WORKING LIGHT ATTACH, OUTPUT

Description: Voltage feed to working light, attachment.

Circuit diagram: Circuit 9.6-2

Contact:
• LE: digital out from D791-1/K1:1 to E404L-3
• RI: digital out from D791-1/K1:15 to E404R-3

Function: 9.6.12 Work light attachment

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

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 8 Control system – LIGHTS 8:33

8.4.2.14 LIGHTS, menu 14

SWITCH LIGHTS, OUTPUT

Description: Voltage feed to background lighting in switches, panels
DIAG LIGHTS 14(X) and keys.
SWITCH LIGHTS Circuit diagram: Circuit 4.0-1, 5.2-1, 7.5-1, 7.9-1, 9.1-1, 9.3-1, 9.3-3,
9.4-1, 9.6-2, 9.6-3, 9.6-4, 9.6-1
OUTPUT XXX

005300
Contact:
output signal from D790-1/K6:1 to S117, S118, S139
output signal from D790-1/K6:2 to S105-2
output signal from D790-1/K6:3 to S105-3
output signal from D790-1/K6:4 to S110
output signal from D790-1/K6:5 to S100
output signal from D790-1/K6:6 to S143
output signal from D790-1/K6:7 to S199-4
output signal from D790-1/K6:8 to S199-3
output signal from D790-1/K6:9 to S199-1
output signal from D790-1/K6:10 to S105-1
output signal from D790-1/K8:10 to S1004
output signal from D790-1/K8:12 to S1003
output signal from D790-1/K8:13 to S107
output signal from D790-1/K8:14 to S199-2
output signal from D790-1/K8:15 to S169, S1010
output signal from D790-1/K9:2 to S160-2

Function: 9.6.11 Interior lighting

Signal value:

50 Means 4-5 V.
170 Means 15-16 V.

8.4.2.15 LIGHTS, menu 15

STEP LIGHT, SWITCH

Description: Signal from entry lighting switch.
DIAG LIGHTS 15(X)
STEP LIGHT Circuit diagram: Circuit 9.6-11
SWITCH X Connection: signal from S141/2 to digital in D790-1/K11:4
OUTPUT XXX
008897

Function: 9.6.13 Entry lighting

Signal value:

1 Input signal active.

0 No signal.

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8:34 8 Control system – CAB

STEP LIGHT, OUTPUT

Description: Voltage feed to entry lighting.
Circuit diagram: Circuit 9.6-11
Connection: digital out from D790-1/K11:6 to E433
Function: 9.6.13 Entry lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which
corresponds to battery voltage).

8.4.3 CAB
CAB, description
This group covers functions in the cab.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005301

OLS EXTRA

8.4.3.1 CAB, menu 1

WASHER, SWITCH
Description: Signal from gear and multi-function lever switch washer.
DIAG CAB 1(X)
WASHER Circuit diagram: Circuit 9.5-1
SWITCH X Connection: signal from S162/53C to digital in D790-2/K3:4
OUTPUT FRONT XY
005541

OUTPUT REAR ROOF XY Function: 9.5 Wiper/washer system

Signal value:

1 Input signal active.

0 No signal.

WASHER FRONT, OUTPUT

Description: Voltage feed to windscreen washer motor.
Circuit diagram: Circuit 9.5-1
Connection: digital out from D790-1/K10:13 to M651-1
Function: 9.5.4 Washer motor and reservoir
Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

WASHER REAR ROOF, OUTPUT

Description: Grounding of motor washer roof and rear window. The
motor is supplied with voltage parallel with Motor windscreen washing,
activation is controlled by controlling grounding of the motor. The
motor is grounded at windscreen washing if the wiper motor roof or
rear window is activated.
Circuit diagram: Circuit 9.5-1
Connection: PWM out D790-1/K5:4 to M651-2

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 8 Control system – CAB 8:35

Function: 9.5.4 Washer motor and reservoir

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.3.2 CAB, menu 2

FRONT WIPER, SWITCH (1-3)
Description: Signal from multi-function lever, switch wiper function.
DIAG CAB 2(X)
FRONT WIPER Circuit diagram: Circuit 9.5-1
SWITCH (1-3) X Contact:
OUTPUT XY
005542

FEEDBACK X X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6

X = 2 Interval less slow: signal from S162/J2, digital in
D790-2/K3:7
X = 3 Interval continuous: signal from S162/53, digital in
D790-2/K3:8

Function: 9.5 Wiper/washer system

Signal value:

1 Long interval.
2 Normal interval.
3 Continuous operation.

FRONT WIPER, OUTPUT

Description: Voltage feed to wiper front.
Circuit diagram: Circuit 9.5-1
Connection: digital out from D790-1/K2:1 to M650-1/53
Function: 9.5.5 Wiper motor front
Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

FRONT WIPER, FEEDBACK

Description: Signal from motor wiper front, indicates when the wiper
sweep is completed.
Circuit diagram: Circuit 9.5-1
Connection: signal from M650-1/31B to digital in D790-1/K4:13
Function: 9.5.5 Wiper motor front
Signal value:

1 Input signal active (wiper sweep).

0 No signal (home position).

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8:36 8 Control system – CAB

8.4.3.3 CAB, menu 3

REAR WIPER, SWITCH
Description: Status of rear window wiper switch on Control unit KIT
DIAG CAB 3(X) (D790-2).
REAR WIPER
SWITCH X Circuit diagram: -
OUTPUT XY Contact: -

005543
FEEDBACK X
Function: 9.5 Wiper/washer system

Signal value:

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

0 No signal.

REAR WIPER, OUTPUT

Description: Voltage feed to direction windscreen wiper rear.

Circuit diagram: Circuit 9.5-1

Connection: digital out from D790-1/K2:4 to M650-2/53

Function: 9.5.7 Wiper motor rear

Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

REAR WIPER, FEEDBACK

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

Circuit diagram: Circuit 9.5-1

Connection: signal from M650-2/31b to digital in D790-1/K12:2

Function: 9.5.7 Wiper motor rear

Signal value:

1 Input signal active (wiper sweep).

0 No signal (home position).

8.4.3.4 CAB, menu 4

ROOF WIPER, SWITCH
Description: Signal from switch, wiper roof.
DIAG CAB 4(X)
ROOF WIPER Circuit diagram: -
SWITCH X Contact: -
OUTPUT XY
005544

FEEDBACK X Function: 9.5 Wiper/washer system

Signal value:

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

0 No signal.

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 8 Control system – CAB 8:37

ROOF WIPER, OUTPUT

Description: Voltage feed to wiper roof.

Circuit diagram: Circuit 9.5-1

Connection: digital out from D790-1/K10:14 to wiper motor M650-3/53

Function: 9.5.6 Wiper motor roof

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

ROOF WIPER, FEEDBACK

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

Circuit diagram: Circuit 9.5-1

Connection: signal from M650-3/31B to digital in D790-1/K12:4

Function: 9.5.6 Wiper motor roof

Signal value:

1 Input signal active (wiper sweep).

0 No signal (home position).

8.4.3.5 CAB, menu 5

HORN, SWITCH
Description: Signal from switch, horn.
DIAG CAB 5(X)
HORN Circuit diagram: Circuit 9.7-1
SWITCH X Connection: signal from S162/H to digital in D790-2/K3:2
SWITCH 2 X
005545

OUTPUT XY Function: 9.7 Signalling system

Signal value:

1 Input signal active.

0 No signal.

HORN, SWITCH 2

Description: Signal from horn switch on hydraulic control panel.

Circuit diagram: Circuit 9.7-4

Connection: signal from S149-3 to digital in D790-1/K9:10

Function: 9.7 Signalling system

Signal value:

1 Input signal active.

0 No signal.

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8:38 8 Control system – CAB

HORN, OUTPUT
Description: Voltage feed to horn.

Circuit diagram: Circuits 9.7-1 and 9.7-3

Connection: digital out D790-1/K11:11 to H850 ( for compressor

horn, signal to relay K3016/86)

Function: 9.7.1 Horn

Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

8.4.3.6 CAB, menu 6

BUZZER
Description: Voltage feed to buzzer for alarm indication panel, feed.
DIAG CAB 6(X)
BUZZER XY Circuit diagram: Circuit 9.7-1
SWITCH SEAT X Connection: digital out from D790-2/K8:4 to H853/1
ALARM X
005546

OP X Function: 9.3 Seat, 1 Engine, 8.2.1 Overload system

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

SWITCH SEAT
Description: Signal from Sensor, operator-in-seat.

Circuit diagram: Circuit 9.7-1

Connection: signal from S230/1 to D790-1/K11:14

Function: 9.3.14 Sensor operator in seat

1 Input signal active. Operator in seat.

0 No signal. No operator in seat.

ALARM
Description: Status for alarm indication panel, warning from control
system.

Circuit diagram: -

Contact: -

Function: 8.1.2 Information display

1 Conditions for activation of buzzer from seat switch and

parking brake are fulfilled.
0 Conditions for activation of buzzer are not fulfilled.

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 8 Control system – CAB 8:39

OP
Description: Status for overload protection warning from control
system.
Circuit diagram: Circuit 8.2_2
Contact: -
Function: 8.2.1 Overload system
Signal value:

1 Conditions for activation of buzzer fulfilled, that is, overload

system is indicating.
0 Conditions for activation of buzzer are not fulfilled.

8.4.3.7 CAB, menu 7

FUEL, SENSOR VALUE
Description: Signal from sensor fuel level.
DIAG CAB 7(X)
FUEL Circuit diagram: Circuit 1.0-1
SENSOR VALUE XXXohm Connection: analogue rheostat signal from B757 to D797-1/K2:15
PROC XXX
009182

Function: 1.2.2 Sensor fuel level

Signal value: XXXOHM = Current resistance value from sensor fuel

level in ohm.

FUEL, PROC
Description: The control system's interpretation of the signal from
sensor, fuel tank.
Circuit diagram: -
Contact: -
Function: 1.2.2 Sensor fuel level
Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.

8.4.3.8 CAB, menu 8

SEAT HEATER, SWITCH

DIAG CAB 8(X)

SEAT HEATER Description: Signal from seat heating switch.
SWITCH X
OUTPUT XY Circuit diagram: Circuit 9.3-1
005548

Connection: signal from S143/1 to digital in D790-1/K6:6

Function: 9.3 Seat

Signal value:

1 Input signal active.

0 No signal.

SEAT HEATER, OUTPUT

Description: Voltage feed to seat heating relay.
Circuit diagram: Circuit 9.3-1
Connection: digital out from D790-1/K10:7 to K383/86
Function: 9.3.3 Heating coil

Workshop Manual DCF 80-100 VDCF05.01GB

8:40 8 Control system – CLIMATE

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.4 CLIMATE
CLIMATE, description
This group covers the cab's air conditioning.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005302

OLS EXTRA

8.4.4.1 CLIMATE, menu 1

PRESENT INPUT SIGNAL, REQUIRED TEMP

Description: Set value for desired temperature.
DIAG CLIMATE 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit 9.4-1
REQUIRED TEMP XXX Connection: signal from S117/3 to analogue in D790-1/K5:8
PRESENT TEMP XXX
005549

WATER VALVE FEEDB. XXX Function: 9.4 Heating, ventilation and air conditioning

Signal value: XXX = 160-280 = 16-28 ºC = Preset temperature shown

in tenths of degrees and adjusted in increments of half degrees (200
= 20 ºC). Test by increasing or decreasing temperature with the
temperature switch on the panel.

PRESENT INPUT SIGNAL, PRESENT TEMP

Description: Signal from sensor cab temperature.

Circuit diagram: Circuit 9.4-1

Connection: signal from B775-1/2 to input D790-1/K4:8

Function: 9.4.17 Sensor cab temperature

Signal value: XXX = Cab's interior temperature in tenths of degrees

(200 = 20 ºC).

PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

Description: Water valve's position (opening in percent).

Circuit diagram: Circuit 9.4-2

Connection: signal from Y673/9 to analogue in D790-1/K10:4

Function: 9.4.5 Water valve

Signal value: XXX = 0-100 = 0-100% = Water valve's opening in %. 0

= Closed. 100 = Fully open.

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – CLIMATE 8:41

8.4.4.2 CLIMATE, menu 2

TEMP COIL
Description: Temperature of the air out from the fan. The sensor is
DIAG CLIMATE 2(X) fitted in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit 9.4-1
TEMP AMBIENT XXX Connection: signal from B775-2 to input D790-1/K4:10

005550
TEMP DE-ICE XXX
Function: 9.4.16 Sensor, temperature outlet fan

Signal value: XXX = Temperature of the air blown into the cab in
tenths of degrees (200 = 20 ºC).

TEMP COOLANT
Description: Coolant temperature, temperature of the engine's coolant.
Signal is retrieved from the engine via CAN bus drive-train.
Circuit diagram: Circuit 9.4-1, 9.4-2
Connection: from engine via CAN bus, see PRESENT INPUT SIGNAL,
COOLANT TEMP, page 8:55.
Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = Engine temperature in tenths of degrees (200 =
20 ºC).

TEMP AMBIENT
Description: Outdoor temperature. Heat radiation from engine and sun
may affect the value since the sensor is fitted on the rear of the cab roof.
Circuit diagram: Circuit 9.4-1
Connection: signal from B774/2 to input D790-1/K4:9
Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees (200 =
20 ºC).

TEMP DE-ICE
Description: Temperature in refrigerant circuit.
Circuit diagram: Circuit 9.4-1
Connection: signal from B775-3/2 to input D790-1/K4:11
Function: 9.4.12 Sensor temperature refrigerant
Signal value: XXX = Refrigerant temperature in tenths of degrees
(200 = 20 ºC).

8.4.4.3 CLIMATE, menu 3

PRESENT INPUT SIGNAL, PRESSURE SWITCH
Description: Signal from refrigerant pressure switch.
DIAG CLIMATE 3(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit 9.4-1
PRESSURE SWITCH X Connection: signal from S246/2 to digital in D797-1/K1:40
005551

Function: 9.4.10 Pressure switch

Signal value:

1 Input signal active. Press OK.

0 No signal, too high or too low pressure.

Workshop Manual DCF 80-100 VDCF05.01GB

8:42 8 Control system – CLIMATE

8.4.4.4 CLIMATE, menu 4

PRESENT INPUT SIGNAL, WATER VALVE
Description: Signal from water valve, the voltage is a measure of
DIAG CLIMATE 4(X) the position.
PRESENT INPUT SIGNAL
WATER VALVE XX.XXV Circuit diagram: Circuit 9.4-2
DRAUGHT VALVE XX.XXV Connection: signal from Y673/9 to analogue in D790-1/K10:4

005552
Function: 9.4.5 Water valve

Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, DRAUGHT VALVE

Description: Signal from the engine to the air distributor. The voltage is
a measure of the damper's position.

Circuit diagram: Circuit 9.4-2

Connection: signal from Y672/9 to analogue in D790-1/K4:7

Function: 9.4.14 Air distributor

Signal value: XX.XXV = 0.50 - 4.50 V

8.4.4.5 CLIMATE, menu 5

PRESENT INPUT SIGNAL, REQUIRED TEMP
Description: Signal from switch, temperature. Voltage when the
DIAG CLIMATE 5(X) switch is pressed in the voltage level indicates increase or decrease
PRESENT INPUT SIGNAL of the temperature.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit 9.4-1
005553

REQ. FAN SPEED XX.XXV Connection: signal from S117/3 to analogue in D790-1/K5:8

Function: 9.4 Heating, ventilation and air conditioning

Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Increase / - / decrease.

PRESENT INPUT SIGNAL, REQ. DRAUGHT

Description: Signal from switch, air distribution, voltage when switch is
pressed in. The voltage level indicates change of air control against
windscreen (up) or floor (down). The damper's position changes in
steps between windscreen - floor.

Circuit diagram: Circuit 9.4-1

Connection: signal from S139/3 to analogue in D790-1/K5:9

Function: 9.4 Heating, ventilation and air conditioning

Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Up / - / down.

PRESENT INPUT SIGNAL, FAN SPEED

Description: Signal from switch, fan speed, switch controls increase or
decrease of fan speed. Speed is adjustable steplessly. The voltage
level indicates if the speed should be increased or decreased.

Circuit diagram: Circuit 9.4-1

Connection: signal from S118/3 to analogue in D790-1/K5:7

Function: 9.4 Heating, ventilation and air conditioning

Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Increase / - / decrease.

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – CLIMATE 8:43

8.4.4.6 CLIMATE, menu 6

PRESENT OUTPUT SIGNAL, FAN SPEED

Description: Current control of fan motor, speed is controlled with
DIAG CLIMATE 6(X) PWM-control of grounding (of fan motor).
PRESENT OUTPUT SIGNAL
FAN SPEED XXX Circuit diagram: Circuit 9.4-2
RECIRCULATION XY Connection: analogue out from D790-1/K2:2 to M657/31

013616
COMPRESSOR XY
Function: 9.4.3 cab fan.

Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).

PRESENT OUTPUT SIGNAL, RECIRCULATION

Description: Voltage feed to motor for fresh air and recirculation
damper.

Circuit diagram: Circuit 9.4-2

Connection: digital out from D790-1/K2:3 to M612

Function: 9.4.2 Fresh air and recirculation damper

Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

PRESENT OUTPUT SIGNAL, COMPRESSOR

Description: Voltage feed of AC compressor's electromagnetic clutch.
Controls cut-in and cut-out of the compressor. Two outputs are
connected in parallel to handle the current intensity.

Circuit diagram: Circuit 9.4-2

Connection: digital out from D797-1/K1:25 and D797-1/K1:29 to M645

Function: 9.4.7 Compressor

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

Workshop Manual DCF 80-100 VDCF05.01GB

8:44 8 Control system – CLIMATE

8.4.4.7 CLIMATE, menu 7

OUTPUT WATER VALVE, CLOCKWISE

Description: Voltage feed to water valve, for opening. The valve is
DIAG CLIMATE 7(X) connected to an H-bridge. The signal can only be diagnosed when
OUTPUT WATER VALVE the valve's position changes. The valve's opening and closing is
CLOCKWISE XY XY controlled by the air conditioning's software depending on desired
ANTI-CLOCKWISE XY XY temperature, outside temp. cab temperature and coolant temperature,
so it may be difficult to determine whether the valve is working as it
should.

24V Circuit diagram: Circuit 9.4-2

Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from

D790-1/K4:2 via R4 to Y673/6

Function: 9.4.5 Water valve

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

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
005555

0V 10 Output signal active, short circuit.

11 Output signal active, circuit OK or open circuit. Open circuit
H-bridge can only be detected when the output signal is missing.

OUTPUT WATER VALVE, ANTI-CLOCKWISE

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

Circuit diagram: Circuit 9.4-2

Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from

D790-1/K4:2 via R4 to Y673/6

Function: 9.4.5 Water valve

Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – CLIMATE 8:45

8.4.4.8 CLIMATE, menu 8

OUTPUT DRAUGHT VALVE, CLOCKWISE

Description: Voltage feed to motor for the air distributor, rotation
DIAG CLIMATE 8(X) clockwise. Is connected to an H-bridge. Signal can only be diagnosed
OUTPUT DRAUGHT VALVE when the air distributor's position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit 9.4-2

Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from

D790-1/K4:4 via R6 to Y672/6
24V
Function: 9.4.14 Air distributor

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

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
M can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.
005556

0V

H-bridge

OUTPUT DRAUGHT VALVE, ANTI-CLOCKWISE

Description: Voltage feed to the motor for the air distributor, rotation
anticlockwise. The motor is connected to an H-bridge. The signal can
only be diagnosed when the air distributor's position changes.

Circuit diagram: Circuit 9.4-2

Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from

D790-1/K4:4 via R6 to Y672/6

Function: 9.4.14 Air distributor

Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

Workshop Manual DCF 80-100 VDCF05.01GB

8:46 8 Control system – HYD

8.4.5 HYD
HYD, description
This group covers the hydraulic functions.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH

005303
OLS EXTRA

8.4.5.1 HYD, menu 1

HYDRAULIC OIL, TEMP
Description: Signal from sensor hydraulic oil temperature.
DIAG HYDRAULIC 1(X)
HYDRAULIC OIL Circuit diagram: Circuit 10.6-1
TEMP XXX Connection: signal from B776/1 to temperature in D797-1/K2:13
FAN XY
010070

SET OUTPUT + - X Function: 10.6.4 Sensor hydraulic oil temperature

Signal value: XXX = Temperature in tenths of degrees (200 = 20 ºC).

HYDRAULIC OIL, FAN

Description: Voltage feed cooling fan hydraulic oil.

Circuit diagram: Circuit 10.6-1

Connection: digital out from D797-1/K1:14 to M668/1

Function: 10.6.3 Cooling fan

Signal value:

HYDRAULIC OIL, SET OUTPUT +/-

Description: Functionality test of hydraulic oil cooling fan.

Circuit diagram: Circuit 10.6-1

Connection: digital out from D797-1/K1:14 to M668/1 is activated or

deactivated with +/-

Function: 10.6.3 Cooling fan

Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

8.4.5.2 HYD, menu 2

BRAKE COOLANT OIL, TEMP

DIAG HYDRAULIC 2(X)

BRAKE COOLANT OIL Description: Signal from sensor for oil temperature, brake system.
TEMP XXX
FAN XY Circuit diagram: Circuit 4.8-1
010072

SET OUTPUT + - X
Connection: signal from B772/1 to temperature in D797-1/K2:6

Function: 4.8.10 Sensor hydraulic oil temperature

Signal value: XXX = Temperature in tenths of degrees (200 = 20 ºC).

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 8 Control system – HYD 8:47

BRAKE COOLANT OIL, FAN

Description: Voltage feed to cooling fan for brake system oil.

Circuit diagram: Circuit 4.8-1

Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1

Function: 4.8.9 Cooling fan

Signal value:

BRAKE COOLANT OIL, FEEDBACK

Description: Signal from cooling fan for brake system oil.

Circuit diagram: Circuit 4.8-1

Connection: signal from M674/1 to D797-1/K1:3 via K3774/86

Function: 4.8.9 Cooling fan

Signal value:

BRAKE COOLANT OIL, SET OUTPUT +/-

Description: Voltage feed to cooling fan for brake system oil.

Circuit diagram: Circuit 4.8-1

Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1 is

activated or deactivated with +/-

Function: 4.8.9 Cooling fan

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.5.3 HYD, menu 3

HYDRAULIC PRESSURE, LIFT CYLINDER
Description: Pressure on the lift cylinders' piston side (C+). For
DIAG HYDRAULIC 3(X) voltage value, see PRESENT INPUT SIGNAL, LIFT CYLINDER,
HYDRAULIC PRESSURE page 8:100.

LIFT CYLINDER XXX Circuit diagram: Circuit 8.2-2

TILT CYLINDER XXX Connection: signal from B768-1/3 to analogue in D797-1/K1:21

Function: 7.2.8 Sensor hydraulic pressure lift cylinder

C-
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255
= incorrect signal.)

C+
007239

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8:48 8 Control system – HYD

HYDRAULIC PRESSURE, TILT CYLINDER

Description: Pressure on the tilt cylinders' rod side (C-). For voltage
value, see PRESENT INPUT SIGNAL, TILT CYLINDER, page 8:100.

Circuit diagram: Circuit 8.2-2

Connection: signal from B768-2/3, analogue in D797-1/K1:22

Function: 7.7.8 Hydraulic pressure sensor, tilt cylinder

Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255

= incorrect signal.)

8.4.5.4 HYD, menu 4

PRESSURE SWITCHES, BRAKE PRESSURE

Description: Signal from break contact (opening switch) brake
DIAG HYDRAULIC 4(X) pressure.
PRESSURE SWITCHES
BRAKE PRESSURE X Circuit diagram: Circuit 4.0-1
BRAKE LIGHT PRESS. X Connection: signal from S204/2 to analogue in D797-1/K1:13
007240

DECLUTCH PRESSURE X
Function: 4.3.7 Normally open (NO) switch, brake pressure

Signal value:

1 Input signal active.

0 No signal.

PRESSURE SWITCHES, BRAKE LIGHT PRESSURE

Description: Signal from make-contact (closing switch) 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 (closing switch) brake lights

Signal value:

1 Input signal active.

0 No signal.

PRESSURE SWITCHES, DECLUTCH PRESSURE

Description: Signal from break contact (opening switch) declutch.

Circuit diagram: Circuit 2.0-1

Connection: signal from S220-2/2 to analogue in D797-1/K1:27

Function: 2.8.2 Normally closed (NC) switch, disengagement

Signal value:

1 Input signal active.

0 No signal.

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – HYD 8:49

8.4.5.5 HYD, menu 5

P-BRAKE, SWITCH
Description: Signals from switch parking brake. Two signals, one
DIAG HYDRAULIC 5(X) for released parking brake and one for applied parking brake. Both
P-BRAKE signals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit 4.0-1

007241
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from
S107/7 to digital in D790-1/K8:5

Function: 4.5 Parking brake system

Signal value:

1/0 Open, parking brake released.

0/1 On, parking brake applied.

P-BRAKE, FEEDBACK SWITCH

Description: Signal from break contact (opening switch) parking brake.

Circuit diagram: Circuit 4.0-1

Connection: signal from S200 to analogue in D797-1/K1:41

Function: 4.5.5 Normally open (NO) switch, parking brake

Signal value:

1 Input signal active.

0 No signal.

P-BRAKE, VALVE
Description: Voltage feed to Solenoid valve parking brake.

Circuit diagram: Circuit 4.0-1

Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1

Function: 4.5.3 Solenoid valve parking brake

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

Workshop Manual DCF 80-100 VDCF05.01GB

8:50 8 Control system – HYD

8.4.5.6 HYD, menu 6

CUT OFF HYDRAULIC PUMPS, PUMP 2
Description: Voltage feed to solenoid valve for disconnection of the
DIAG HYDRAULIC 6(X) hydraulic pump.
CUT OFF HYDRAULIC
PUMPS Circuit diagram: Circuit 10.4-1
PUMP 2 XY Connection: digital out from D797-1/K1:39 to solenoid valve Y6062

007242
PUMP ATTACHMENT XY
Function: 10.4.3 Vane pump with fixed displacement

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

CUT OFF HYDRAULIC PUMPS, PUMP ATTACHMENT

Description: Voltage feed to solenoid valve for disconnection of the
hydraulic pump for the attachment.

Circuit diagram: Circuit 10.4-1

Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2

Function: 10.4.2 Axial piston pump with variable displacement

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.5.7 HYD, menu 7

PRESENT OUTPUT SIGNAL EXTRA HYD PUMP,
VALVE
Description: Voltage feed to solenoid valve for quick-lift pump.
DIAG HYDRAULIC 7(X)
PRESENT OUTPUT SIGNAL Circuit diagram: 10.4-1
EXTRA HYD PUMP Connection: digital out from D797-1/K1:39 to solenoid valve Y6062
VALVE XY
010073

SET OUTPUT + - X Function: 10.4.2 Axial piston pump with variable displacement

Signal value:

1 Output signal active.

0 No output signal.

PRESENT OUTPUT SIGNAL EXTRA HYD PUMP, SET

OUTPUT +/-
Description: Activate or deactivate the quick-lift pump.

Circuit diagram: 10.4-1

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – ENGINE 8:51

Connection: digital out from D797-1/K1:39 to solenoid valve Y6062 is

activated or deactivated with +/-

Function: 10.4.2 Axial piston pump with variable displacement

Signal value:

1 Output signal active.

0 No output signal.

8.4.5.8 HYD, menu 8

PRESENT OUTPUT SIGNAL, PRESSURE TO

ATTACHM. VALVE
Description: Voltage feed to solenoid valve for main pump relief
DIAG HYDRAULIC 8(X) (pressurised attachment).
PRESENT OUTPUT SIGNAL
PRESSURE TO ATTACHM. Circuit diagram: 10.4-1
VALVE XY Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2
010074

SET OUTPUT + - X
Function: 10.4.2 Axial piston pump with variable displacement

Signal value:

1 Output signal active.

0 No output signal.

PRESENT OUTPUT SIGNAL, PRESSURE TO

ATTACHM, SET OUTPUT +/-
Description: Begin sending or cut off hydraulic pressure to the
attachment.

Circuit diagram: 10.4-1

Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2

is activated or deactivated with +/-

Function: 10.4.2 Axial piston pump with variable displacement

Signal value:

1 Output signal active.

0 No output signal.

8.4.6 ENGINE
ENGINE, description
This group covers engine functions.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005306

OLS EXTRA

Workshop Manual DCF 80-100 VDCF05.01GB

8:52 8 Control system – ENGINE

8.4.6.1 ENGINE, menu 1

PRESENT INPUT SIGNAL, ACCELERATOR

Description: Signal from accelerator pedal.
DIAG ENGINE 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit 1.0-1
ACCELERATOR X.XXV Connection: signal from B690-1/2 to analogue in D790-1/K6:11
REQUIRED SPD PROC XXX

008898
REQUIRED SPD RPM XXXX Function: 1 Engine

Signal value: X.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED SPD PROC

Description: Required engine speed (in percent) which is sent from
Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus
drive-train.

Circuit diagram: -

Contact: -

Function: 1.9 Control system, engine

Signal value: XXXX = 0 - 100%

PRESENT INPUT SIGNAL, REQUIRED SPD RPM

Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN
bus drivetrain.

Circuit diagram: -

Contact: -

Function: 1.9 Control system, engine

Signal value: XXXX = 0-2010 rpm

8.4.6.2 ENGINE, menu 2

RESENT INPUT SIGNAL, ENGINE SPEED EDC

Description: Engine speed from Control unit, engine (D794) to Control
DIAG ENGINE 2(X) unit, cab (D790-1) via CAN bus drive-train. Actual value for engine
PRESENT INPUT SIGNAL speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
005308

Contact: -

Function: 1.9.2 Sensor engine rpm

Signal value: XXXX = active speed in rpm.

PRESENT INPUT SIGNAL, ENGINE SPEED TCU

Description: Engine speed from Control unit, transmission (D793) to
Control unit, cab (D790-1) via CAN bus drive-train. Actual-value for
engine speed, engine.

Circuit diagram: -

Contact: -

Function: 2.2.5 Sensor engine speed and oil temperature transmission

Signal value: XXXX = active speed in rpm.

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – ENGINE 8:53

8.4.6.3 ENGINE, menu 3

PRESENT INPUT SIGNAL, PRESENT TORQUE
Description: Actual torque from Control unit, engine (D794).
DIAG ENGINE 3(X) Percentage torque use of engine's capacity.
PRESENT INPUT SIGNAL
PRESENT TORQUE XXX Circuit diagram: -
REQUIRED TORQUE XXX Contact: -

005309
PRES TORQUE @ RPM XXX
Function: 1.9 Control system, engine

Signal value: XXXX = 0 - 100%

PRESENT INPUT SIGNAL, REQUIRED TORQUE

Description: Requested torque from cab control unit (D790-1) to engine
control unit (D794).

Circuit diagram: -

Contact: -

Function: 1.9 Control system, engine

Signal value: XXXX = 0-100%

PRESENT INPUT SIGNAL, PRES TORQUE @ RPM

Description: Available torque at current engine speed.

Circuit diagram: -

Contact: -

Function: 1.9 Control system, engine

Signal value: XXX = 0-100%

8.4.6.4 ENGINE, menu 4

PRESENT INPUT SIGNAL, PREHEAT SWITCH
Description: Signal from ignition key lock, preheating position.
DIAG ENGINE 4(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit 11.5-3, 1.0-1
PREHEAT SWITCH X Connection: signal from S150/19 to digital in D790-2/K2:2
CRANK ENGINE SWITCH X
005310

D+ X Function: 1 Engine, 1.10.1 Preheating

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

Description: Signal from ignition key lock, start position.

Circuit diagram: Circuit 11.5-3, 1.0-1

Connection: signal from S150/50 to digital in D790-2/K2:1

Function: 1.1.1 Ignition switch, 1.11 Start and stop

Signal value:

1 Input signal active.

0 No signal.

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PRESENT INPUT SIGNAL, D+

Description: Signal from alternator, indicates if alternator supplies
current.

Circuit diagram: Circuit 11.5-1, 1.0-2F, 1.0-1

Connection: signal from G660/D+ to digital in D797-1/K2:16

Function: 11.4.1 Alternator

Signal value:

1 Input signal active.

0 No signal.

8.4.6.5 ENGINE, menu 5

PRESENT OUTPUT SIGNAL, PREHEAT
Description: Status for preheating of induction air.
DIAG ENGINE 5(X)
PRESENT OUTPUT SIGNAL Circuit diagram: -
PREHEAT X Contact:
CRANK ENGINE CAN X
007639

CRANK ENGINE WIRE XY Software signals on CAN-bus drive-train

Function: 1.10.1 Preheating

Signal value:

1 Output signal active.

0 No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE CAN

Description: Voltage feed starter motor.

Circuit diagram: -

Connection: software signals on CAN-bus drivetrain.

Function: 1.11 Start and stop

Signal value:

1 Output signal active.

0 No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE WIRE

Not used.

8.4.6.6 ENGINE, menu 6

PRESENT INPUT SIGNAL, OIL PRESSURE
Description: Engine oil pressure. CAN bus message from Control
DIAG ENGINE 6(X) unit, engine (D794) to Control unit, cab (D790-1).
PRESENT INPUT SIGNAL
OIL PRESSURE XX.X Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XX.X Contact:
008899

OIL LEVEL XXX

Volvo TAD762VE: signal from "24 oil pressure sensor" to engine
control unit (D794) "Connector B" sleeve 11

Function: 1.8.3 Sensor oil pressure engine

Signal value= XX.X = pressure in bar.

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PRESENT INPUT SIGNAL, BOOST PRESSURE

Description: Boost pressure. CAN bus message from Control unit,
engine (D794) to Control unit, cab (D790-1).

Circuit diagram: See supplier documentation, engine

Contact:
Volvo TAD762VE: signal from "9 charge air pressure sensor" to
engine control unit (D794) "Connector A" sleeve 22

Function: 1.6.5 Sensor boost pressure

Signal value= XX.X = pressure in bar.

PRESENT INPUT SIGNAL, OIL LEVEL

Not used.

8.4.6.7 ENGINE, menu 7

PRESENT INPUT SIGNAL, OIL TEMP

Description: Engine oil temperature. CAN bus message from Control
DIAG ENGINE 7(X) unit, engine (D794) to Control unit, cab (D790-1).
PRESENT INPUT SIGNAL
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX Contact:
005313

INTAKE MAIN.TEMP XXX

Volvo TAD762VE: signal from "38 oil temperature/level sensor" to
engine control unit (D794) "connector A" sleeve 31

Function: 1.8.7 Sensor oil temperature

Signal value: XXX = 200 corresponds to 20 ºC.

PRESENT INPUT SIGNAL, COOLANT TEMP

Description: Coolant temperature. CAN bus message from Control
unit, engine (D794) to Control unit, cab (D790-1).

Circuit diagram: see supplier documentation, engine

Contact:
Volvo TAD762VE: signal from "8 coolant temperature sensor" to
engine control unit (D794) "Connector B" sleeve 27

Function: 1.7.9 Sensor coolant temperature

Signal value: XXX = 200 corresponds to 20 ºC.

PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

Description: Charge air temperature. CAN bus message from Control
unit, engine (D794) to Control unit, cab (D790-1).

Circuit diagram: see supplier documentation, engine

Contact:
Volvo TAD762VE: signal from "9 charge air pressure/temperature
sensor" to engine control unit (D794) "connector A" sleeve 47

Function: 1.6.6 Sensor charge-air temperature

Signal value: XXX = 200 corresponds to 20 ºC.

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8.4.6.8 ENGINE, menu 8

PRESENT EDC ERROR, NO. OF ACT ERROR
Description: Number of error codes from engine control unit EDC
DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX Contact: -

005314
FMI XX
Function: 1.9 Control system

Signal value: XX = number of active error codes.

PRESENT EDC ERROR, SPN

Description: SPN number for the first error code from Control unit,
engine (D794). SPN indicates the malfunction area, i.e. what
component or signal is defective. Error codes are shown with SPN/FMI
in the error code menus.

Circuit diagram: -

Contact: -

Function: 8.3 Error codes

Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.

PRESENT EDC ERROR, FMI

Description: FMI number for the first error code from the Control unit,
engine (D794). FMI indicates error type, e.g. short circuit or low value.
Error codes are shown with SPN/FMI in the error code menus.

Circuit diagram: -

Contact: -

Function: 8.3 Error codes

Signal value: XX = fault type number. Use the error code list; see
section D Error codes.

8.4.6.9 ENGINE, menu 9

FUEL CONSUMPTION, MOMENTARY l/h
Description: Current fuel consumption in litres/hour.
DIAG ENGINE 9(X)
FUEL CONSUMPTION Circuit diagram: -
MOMENTARY l/h XXX Contact: -
005315

Function: 1.2 Fuel system

Signal value: XXX = fuel consumption in l/h

8.4.6.10 ENGINE, menu 10

EATS STATUS, TANK LEVEL
Description: AdBlue level in the tank.
DIAG ENGINE 10(X)
EATS STATUS Circuit diagram: Circuit Engine D7
TANK LEVEL XX Contact:
TANK TEMP XX
014745

IND. SEVERITY XX Function:

Signal value: XX = denoted in %

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 8 Control system – TRANSM 8:57

EATS STATUS, TANK TEMP

Description: AdBlue temperature.
Circuit diagram:
Contact:
Function:
Signal value: XX = in degrees

EATS STATUS, IND. SEVERITY

Description: Status code from Volvo.
Circuit diagram:
Contact:
Function:
Signal value:

8.4.7 TRANSM
TRANSM, description
This group covers transmission functions.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005324

OLS EXTRA

8.4.7.1 TRANSM, menu 1

PRESENT INPUT SIGNAL, BRAKE PEDAL
Description: Not used.

PRESENT INPUT SIGNAL, DECLUTCH SWITCH

Description: Signal from declutch pedal.
DIAG TRANSM. 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit 2.0-1
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
005325

DECLUTCH PRESS SW. X Function: 2 Transmission

Signal value:

1 Input signal active. Declutch pedal depressed.

0 No signal.

PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

Description: Signal from break contact (opening switch) declutch
(pressure switch).
Circuit diagram: Circuit 2.0-1
Connection: signal from S220-2/2 to digital in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:

1 Input signal active.

0 No signal.

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8.4.7.2 TRANSM, menu 2

SWITCHES, FORWARD
Description: Signal from gear and multi-function lever (forward).
DIAG TRANSM. 2(X)
SWITCHES Circuit diagram: Circuit 2.0-1
FORWARD X Connection: signal from S162/F to digital in D790-2/K3:11
REVERSE X

005326
SHIFT MODE X Function: 2 Transmission

Signal value:

1 Input signal active. Travel direction forward selected.

0 No signal.

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

Circuit diagram: Circuit 2.0-1

Connection: signal from S162/R to digital in D790-2/K3:12

Function: 2 Transmission

Signal value:

1 Input signal active. Travel direction reverse selected.

0 No signal.

SWITCHES, SHIFT MODE

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

Circuit diagram: -

Contact: -

Function: 2 Transmission

Signal value:

1 Shifting program 1 selected.

2 Shifting program 2 selected.
4 Automatic shifting selected.

8.4.7.3 TRANSM, menu 3

PRESENT VALUE, FORWARD
Description: Status for forward direction of travel from Control unit,
DIAG TRANSM. 3(X) transmission (D793). Indicates if forward drive is activated in the
PRESENT VALUE transmission.
FORWARD X
REVERSE X Circuit diagram: -
005327

GEAR X Contact: -

Function: 2.8 Control system, transmission

Signal value:

1 Output signal for travel direction forward active.

0 No output signal.

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PRESENT VALUE, REVERSE

Description: Status for rearward direction of travel from Control unit,
transmission (D793). Indicates if rearward drive is activated in the
transmission.
Circuit diagram: -
Contact: -
Function: 2.8 Control system, transmission
Signal value:

1 Output signal for travel direction reverse active.

0 No output signal.

PRESENT VALUE, GEAR

Description: Current gear, status from Control unit, transmission
(D793). Shows which gear is activated in the transmission.
Circuit diagram: -
Function: 2.8 Control system, transmission
Contact: -
Signal value: X = current gear.

8.4.7.4 TRANSM, menu 4

OPERATING STATE, AUT/MAN MODE
Description: Shows which shifting program is selected automatic or
DIAG TRANSM. 4(X) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X Contact: -
005328

OPERATING MODE X
Function: 2.8 Control system, transmission

Signal value:

1 Automatic.
0 Manual.

OPERATING STATE, WARNING

Description: Warning for serious malfunction in transmission from
Control unit, transmission (D793).
Circuit diagram: -
Contact: -
Function: 2.8 Control system, transmission
Signal value:

1 Active error.
0 No errors.

OPERATING STATE, OPERATING MODE

Description: Operating mode status for Control unit, transmission
(D793), also shown in control unit display.
Circuit diagram: -
Contact: -

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8:60 8 Control system – TRANSM

Function: 2.8 Control system, transmission

Signal value:

0 Not used.
1 Manual or automatic shifting, standard mode shown during
operation.
2 Not used.
3 Not used.
4 Limp home, reduced capacity due to malfunction in
transmission.
5 Shut down, serious transmission malfunction control unit
shuts down, likely that malfunction cannot be shown as
CAN-bus.
6 Calibration of transmission in progress.

8.4.7.5 TRANSM, menu 5

OPERATING STATE, SHIFT IN PROGRESS
Description: Status for transmission function during operation, shifting
DIAG TRANSM. 5(X) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X Contact: -
005329

OLD FAULT X
Function: 2.8 Control system, transmission

Signal value:

1 Shifting in progress.
0 No activity.

OPERATING STATE, FAULT

Description: Status for transmission's function during operation, active
error codes present.
Circuit diagram: -
Contact: -
Function: 2.8 Control system, transmission
Signal value:

1 Active error code.

0 No error codes.

OPERATING STATE, OLD FAULT

Description: Status for transmission's function during operation, there
are inactive error codes that have not been acknowledged.
Circuit diagram: -
Contact: -
Function: 2.8 Control system, transmission
Signal value:

1 There are inactive error codes that have not been

acknowledged.
0 No unacknowledged error codes.

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 8 Control system – TRANSM 8:61

8.4.7.6 TRANSM, menu 6 (transmission option TE17)

DRUM SPEED
Description: Signal from sensor rpm drum (position 1).
DIAG TRANSM. 6(X)
DRUM SPEED XXXXHz Circuit diagram: Circuit 2.0-2B2
OUTPUT SPEED XXXXHz Connection: signal from B752 till D793/B3 and D793/C3
ENGINE SPEED XXXXHz
TURBINE SPEED XXXXHz Function: 2.3.7 Sensor rpm drum

Signal value: XXXXHz = frequency, indicates pulses from the sensor

1 2 3 in Hz (pulses/second). In order to convert the speed, divide the
frequency by the number of teeth on the drum cog.

5
005330

4
1. Sensor, drum rpm (B752)
2. Temperature monitor torque converter (S221)
3. Sensor, engine speed and transmission
temperature (B758/766)
4. Turbine speed sensor transmission (B751)
5. Sensor rpm output shaft (B758)

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

Circuit diagram: Circuit 2.0-2B2

Connection: signal from B758 till D793/ D3 and D793/ E3

Function: 2.3.9 Sensor rpm output shaft

Signal value: XXXXHz = frequency, indicates pulses from the sensor in

Hz (pulses/second). In order to convert the speed, divide the frequency
by the number of teeth on the output shaft cog.

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8:62 8 Control system – TRANSM

ENGINE SPEED
Description: Rpm signal from sensor rpm engine speed (position 3).

Circuit diagram: Circuit 2.0-2B2

Contact: Signal from B758/766 to D793/F3

Function: 2.2.5 Sensor engine speed and oil temperature transmission

Signal value: XXXXHz = frequency, indicates pulses from the sensor in

Hz (pulses/second). In order to convert the speed, divide the frequency
by the number of teeth on the input shaft cog.

TURBINE SPEED
Description: Signal from sensor rpm turbine transmission (position 4).

Circuit diagram: Circuit 2.0-2B2

Connection: signal from B751 to D793/ R2

Function: 2.3.6 Sensor rpm turbine

Signal value: XXXXHz = frequency, indicates pulses from the sensor in

Hz (pulses/second). In order to convert the speed, divide the frequency
by the number of teeth on the turbine cog.

8.4.7.7 TRANSM, menu 7 (transmission option TE17)

OUTPUT STATUS, RSP DRIVE

Description: Status high and low side for control of solenoid valve
DIAG TRANSM. 7(X) RSP Drive.
OUTPUT STATUS
RSP DRIVE X X Circuit diagram: Circuit 2.0-2B3
2/4 VFS SELECTION X Connection: signal from D793/K1 and D793/K2 to Y6066
005331

1/3 VFS SELECTION X

Function: 2.8 Control system, transmission

11 Activated high and low side.

10 High side activated, low side no signal.
01 High side no signal, low side activated.
00 No signal.

OUTPUT STATUS, 2/4 VFS SELECTION

Description: Status of feed to solenoid valve VFS 2ND/4TH.

Circuit diagram: Circuit 2.0-2B3

Connection: digital out from D793/ D1 and D793/ E1 to Y1

Function: 2.8 Control system, transmission

Signal value:

1 Activated.
0 No signal.

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OUTPUT STATUS, 1/3 VFS SELECTION

Description: Status of feed to solenoid valve VFS 1ST/3RD.
Circuit diagram: Circuit 2.0-2B3
Connection: signal from D793/ H1 and D793/ J1 to Y6067
Function: 2.8 Control system, transmission
Signal value:

1 Activated.
0 No signal.

8.4.7.8 TRANSM, menu 8 (transmission option TE17)

FWD SUPPLY
Description: Status for control current to clutch pack forward.
DIAG TRANSM. 8(X)
FWD SUPPLY X Circuit diagram: Circuit 2.0-2B3
REV SUPPLY X Connection: signal from D793/B1 to Y630
2/4 SUPPLY X
005332

1/3 SUPPLY X Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission

Signal value:

1 Activated.
0 No signal.

REV SUPPLY
Description: Status for control current to clutch pack backward.
Circuit diagram: Circuit 2.0-2B3
Connection: signal from D793/F1 to Y631
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value:

1 Activated.
0 No signal.

2/4 SUPPLY
Description: Status for control current to clutch pack 2/4.
Circuit diagram: Circuit 2.0-2B3
Connection: signal from D793/E2 to Y6074
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value:

1 Activated.
0 No signal.

1/3 SUPPLY
Description: Status for control current to clutch pack 1/3.
Circuit diagram: Circuit 2.0-2B3

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8:64 8 Control system – TRANSM

Connection: signal from D793/F2 to Y6075

Function: 2.3.5 Valve block, transmission control, 2.8 Control system,

transmission

Signal value:

1 Activated.
0 No signal.

8.4.7.9 TRANSM, menu 9 (transmission option TE17)

FWD FEEDBACK
Description: Present control current to solenoid valve clutch pack
DIAG TRANSM. 9(X) forward.
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Circuit diagram: Circuit 2.0-2B3
2/4 FEEDBACK XXXXmA Connection: signal from D793/B1 to Y630
005333

1/3 FEEDBACK XXXXmA

Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission

Signal value: XXXX = Measured value in mA.

REV FEEDBACK
Description: Present control current to solenoid valve clutch pack
backward.

Circuit diagram: Circuit 2.0-2B3

Connection: signal from D793/F1 to Y631

Function: 2.3.5 Valve block, transmission control, 2.8 Control system,

transmission

Signal value: XXXX = Measured value in mA.

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

Circuit diagram: Circuit 2.0-2B3

Connection: signal from D793/D1 to Y6069

Function: 2.3.5 Valve block, transmission control, 2.8 Control system,

transmission

Signal value: XXXX = Measured value in mA.

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

Circuit diagram: Circuit 2.0-2B3

Connection: signal from D793/H1 to Y6067

Function: 2.3.5 Valve block, transmission control, 2.8 Control system,

transmission

Signal value: XXXX = Measured value in mA.

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 8 Control system – TRANSM 8:65

8.4.7.10 TRANSM, menu 10 (transmission option TE17)

PRESENT SENSOR INPUT, PRESS FEEDB.

Description: Signal from the oil pressure sensor in the transmission.
DIAG TRANSM. 10(X) The transmission uses a pressure-sensitive make-contact (closing
PRESENT SENSOR INPUT switch) and two resistors in the wiring to create different voltage levels.
PRESS FEEDB XXXXohm
TRANSM.TEMP XXXXXmV Circuit diagram: Circuit 2.0-2B2

008900
CONV OUT TEMP XXXXXmV Connection: signal from "pressure feedback sensor" to D793/A2

Function: 2.6.2 Sensor oil pressure

Signal value:

0-1000 mV Short-circuiting to ground.

1500-2500 mV Oil pressure is correct.
2500-4000 mV Oil pressure is low.
4500-8000 mV Open circuit.
Over 8000 mV Short circuit to voltage.

PRESENT SENSOR INPUT, TRANS.TEMP

Description: Signal from transmission oil temperature sensor.

Circuit diagram: Circuit 2.0-2B2

Connection: signal from B758/766 to D793/H3

Function: 2.7.2 Sensor engine rpm and oil temperature transmission

Signal value: XXXX mV = signal voltage in mV (0-5000mV).

PRESENT SENSOR INPUT, CONV. OUT TEMP

Description: Signal from the oil temperature sensor out from the
transmission to the radiator. The transmission uses a temperature
sensitive make-contact (closing switch) and two resistors in the wiring
to create different voltage levels.

Circuit diagram: Circuit 2.0-2B2

Connection: signal from S221 to D793/J3

Function: 2.7.4 Sensor oil temperature oil cooler

Signal value:

0 mV Transmission oil has operating temperature.

2500 mV Transmission oil temperature is low.

8.4.7.11 TRANSM, menu 11 (transmission option TE17)

AXLE RATIO
Description: Drive axle's gear ratio.
DIAG TRANSM. 11(X)
PRESENT VALUE Circuit diagram: -
AXLE RATIO XXXXX Contact: -
RADIUS XXXX
005335

Function: 2.8 Control system, transmission

Signal value: XXXXX = drive axle's total gear ratio x 1024.

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8:66 8 Control system – TRANSM

RADIUS
Description: Drive wheel's radius.

Circuit diagram: -

Contact: -

Function: 2.8 Control system, transmission

Signal value: XXXX = Drive wheels' radius in mm.

8.4.7.12 TRANSM, menu 12

SPEED LIMIT, CAB

Description: Speed limitation from D790-1, e.g. emergency stop
DIAG TRANSM. 12(X) switch activated, reversible driver's seat out of position or constant
SPEED LIMIT speed limitation.
SPD GEAR LOG
CAB XX X XX Circuit diagram: -
005336

FRAME XX X XX Contact: -

Function: 8.2.3 Speed limitation

Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed
limitation.

SPEED LIMIT, FRAME

Description: Speed limitation from D797-1 or D797-2, e.g. cab tilted,
load not in transport position during transport.

Circuit diagram: -

Contact: -

Function: 8.2.3 Speed limitation

Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed
limitation.

8.4.7.13 TRANSM, menu 13

ACT ERROR AREA

Description: Indicates malfunction area active error, first part of the
DIAG TRANSM. 13(X) error code. In the event of several error codes, the most serious error
ACT ERROR AREA XXX code is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
005337

TIME AGO XXXXX Contact: -

Function: 2.8 Control system, transmission

Signal value: XXX = First part of error code; see section D Error
codes.

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 8 Control system – TRANSM 8:67

TYPE
Description: Indicates type of active error.

Circuit diagram: -

Contact: -

Function: 2.8 Control system, transmission

Signal value: XXX = Second part of error code.

NUMBER OF OCCU.
Description: Number of times active errors have occurred.

Circuit diagram: -

Contact: -

Function: 2.8 Control system, transmission

Signal value: XXXXX = Number of times active errors have occurred.

TIME AGO
Description: When latest active error occurred.

Circuit diagram: -

Contact: -

Function: 2.8 Control system, transmission

Signal value: XXXXX = Operating time in hours since latest error.

8.4.7.14 TRANSM, menu 14

CONVERTER STATUS (Nm), TORQUE IMPELLER

Description: Torque transmitted from the engine to the impeller in the
DIAG TRANSM. 14(X) torque converter. The torque absorbed by the transmission.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Contact: -
007622

Function: 2.8 Control system, transmission

Signal value: XXXX = Torque in Nm.

CONVERTER STATUS (Nm), TORQUE TURBINE

Description: Current torque transmitted by torque converter to the
transmission.

Circuit diagram: -

Contact: -

Function: 2.8 Control system, transmission

Signal value: XXXX = Torque in Nm.

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8.4.8 ELSERV
ELSERV, description

DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers electric servo functions.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH Confirm selections with function key for Enter.

005400
OLS EXTRA

8.4.8.1 ELSERV, menu 1

PRESENT INPUT SIGNALS, P1
Description: Signal from control lever P1.
DIAG ELSERVO 1(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.0-1, 7.0-2
P1 XX.XXV Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3
P2 XX.XXV
005401

P3 XX.XXV Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P2

Description: Signal from control lever P2.
Circuit diagram: Circuit 7.0-1, 7.0-2
Connection: signal from R8072/3 (S815/4) to analogue in D790-1/K7:4
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P3

Description: Signal from control lever P3.
Circuit diagram: Circuit 7.0-1, 7.0-2
Connection: signal from R8073/3 (S815/11) to analogue in D790-1/K7:5
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

8.4.8.2 ELSERV, menu 2

PRESENT INPUT SIGNALS, P4
Description: Signal from control lever P4.
DIAG ELSERVO 2(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.0-1, 7.0-2
P4 XX.XXV Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
P7 XX.XXV
005402

P5 XX.XXV Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P7

Description: Signal from control lever P7.
Circuit diagram: Circuit 7.0-1
Connection: signal from R8075-2/3 to analogue in D790-1/K9:9
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

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PRESENT INPUT SIGNALS, P5

Description: Signal from control lever P5.

Circuit diagram: Circuit 7.0-1

Connection: signal from R8075-1/3 to analogue in D790-1/K7:7

Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

8.4.8.3 ELSERV, menu 3

OUTPUT LIFT, REFERENCE

Description: Status for control current to control valve (solenoid valve,
DIAG ELSERVO 3(X) lift mast).
OUTPUT LIFT
REFERENCE XY Circuit diagram: Circuit 7.2-1
REQUIRED VALUE XXXmA Contact: digital output from D797-1/K1:4 to Y6005/1.
005403

FEEDBACK XXXmA
Function: 7.2.5 Control valve, lift and tilt

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT LIFT, REQUIRED VALUE

Description: Reference value for control current to control valve
(solenoid valve, lift mast).

Circuit diagram: Circuit 7.2-1

Connection: output signal reference value out from D797-1/K1:16 to

Y6005/2.

Function: 7.2.5 Control valve, lift and tilt

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT LIFT, FEEDBACK

Description: Current value for control current to control valve (solenoid
valve, lift mast).

Circuit diagram: Circuit 7.2-1

Connection: output signal, actual value out from D797-1/K1:16 to

Y6005/2 (Y6005-1/2 on machines with freelift).

Connection: output signal, actual value out from D797-1/K1:16 to

Y6005/2.

Function: 7.2.5 Control valve, lift and tilt

Signal value: XXX = Measured current value in mA.

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8:70 8 Control system – ELSERV

8.4.8.4 ELSERV, menu 4

OUTPUT LOWER, REFERENCE

Description: Status for control current to control valve (solenoid valve,
DIAG ELSERVO 4(X) lower mast).
OUTPUT LOWER
REFERENCE XY Circuit diagram: Circuit 7.2-1
REQUIRED VALUE XXXmA Contact: digital output from D797-1/K1:4 to Y6004/1.

005404
FEEDBACK XXXmA
Function: 7.2.5 Control valve, lift and tilt

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT LOWER, REQUIRED VALUE

Description: Reference value for control current to control valve
(solenoid valve, lower mast).

Circuit diagram: Circuit 7.2-1

Connection: output signal reference value out from D797-1/K1:17 to

Y6004/2.

Function: 7.2.5 Control valve, lift and tilt

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT LOWER, FEEDBACK

Description: Current value for control current to control valve (solenoid
valve, lower mast).

Circuit diagram: Circuit 7.2-1

Connection: output signal, actual value out from D797-1/K1:17 to

Y6004/2.

Function: 7.2.5 Control valve, lift and tilt

Signal value: XXX = Measured current value in mA.

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – ELSERV 8:71

8.4.8.5 ELSERV, menu 5

OUTPUT TILT IN, REFERENCE

Description: Status for control current to control valve (solenoid valve,
DIAG ELSERVO 5(X) tilt in).
OUTPUT TILT IN
REFERENCE XY Circuit diagram: Circuit 7.7-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6011/1

005405
FEEDBACK XXXmA
Function: 7.7.5 Control valve, lift and tilt

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT TILT IN, REQUIRED VALUE

Description: Reference value for control current to control valve
(solenoid valve, tilt in).

Circuit diagram: Circuit 7.7-1

Connection: output signal reference value out from D797-1/K1:18 to

Y6011/2

Function: 7.7.5 Control valve, lift and tilt

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT TILT IN, FEEDBACK

Description: Current value for control current to control valve (solenoid
valve, tilt in).

Circuit diagram: Circuit 7.7-1

Connection: output signal, actual value out from D797-1/K1:18 to

Y6011/2

Function: 7.7.5 Control valve, lift and tilt

Signal value: XXX = Measured current value in mA.

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8:72 8 Control system – ATTACH, lifting hook attachment

8.4.8.6 ELSERV, menu 6

OUTPUT TILT OUT, REFERENCE

Description: Status for control current to control valve (solenoid valve,
DIAG ELSERVO 6(X) tilt out).
OUTPUT TILT OUT
REFERENCE XY Circuit diagram: Circuit 7.7-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6010/1

005406
FEEDBACK XXXmA
Function: 7.7.5 Control valve, lift and tilt

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT TILT OUT, REQUIRED VALUE

Description: Reference value for control current to control valve
(solenoid valve, tilt out).

Circuit diagram: Circuit 7.7-1

Connection: output signal, reference value out from D797-1/K1:19,

to solenoid valve Y6010/1

Function: 7.7.5 Control valve, lift and tilt

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT TILT OUT, FEEDBACK

Description: Current value for control current to control valve (solenoid
valve, tilt out).

Circuit diagram: Circuit 7.7-1

Connection: output signal, actual value out from D797-1/K1:19 to

solenoid valve Y6010/2

Function: 7.7.5 Control valve, lift and tilt

Signal value: XXX = Measured current value in mA.

8.4.9 ATTACH, lifting hook attachment

ATTACH, description
This group covers attachment functions.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005339

OLS EXTRA

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 8 Control system – ATTACH, lifting hook attachment 8:73

8.4.9.1 ATTACH, menu 1

PRESENT INPUT SIGNALS, P3
Description: Signal from control lever P3.
DIAG ATTACHMENT 1(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.0-1, 7.0-2
P3 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in
P4 XX.XXV D790-1/K7:5

005416
P7 XX.XXV
Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P4

Description: Signal from control lever P4.
Circuit diagram: Circuit 7.0-1, 7.0-2
Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P7

Description: Signal from control lever P7.
Circuit diagram: Circuit 7.0-1
Connection: signal from R8075-2/3 to analogue in D790-1/K9:9
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

8.4.9.2 ATTACH, menu 2

PRESENT INPUT SIGNALS, P5
Description: Signal from control lever P5.
DIAG ATTACHMENT 2(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.0-1
P5 XX.XXV Connection: signal from R8075-1/3 to analogue in D790-1/K7:7
005417

Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

8.4.9.3 ATTACH, menu 3

PRESENT INPUT SIGNALS, SPREADER
Description: Signals from switch for spreading the attachment.
DIAG ATTACHMENT 3(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.5-1, 7.0-2
SPREADER IN X OUT X Contact:
AUTO 20/40 X
IN: Signal from S1012/1 (S815/14) to digital in D790/K7:14
005418

30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790/K7:13
(spreading out)

Function: 7.1.3 Switch, spreading 20'-40', 7.1.1 Control lever

Signal value:

1 Input signal active.

0 No signal.

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8:74 8 Control system – ATTACH, lifting hook attachment

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/K8:11
Function: 7.5 Spreading
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, 30/35 STOP

Description: Signal from switch for stop at 30'/35'.

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

1 Input signal active.

0 No signal.

8.4.9.4 ATTACH, menu 4

PRESENT INPUT SIGNALS, PISTOL
Description: Signals from control lever for pistol trigger.
DIAG ATTACHMENT 4(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.0-2

Connection: from S815/19 to digital in D790-1/K7:16

PISTOL X
007130

Function: 7.1.1 Control lever

Signal value:

1 Input signal active.

0 No signal.

8.4.9.5 ATTACH, menu 5

PRESENT INPUT SIGNALS, LOCK CONT
Description: Signal from switch, lock lock tongue.
DIAG ATTACHMENT 5(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.9-1
LOCK CONT X Contact: Signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
010079

Function: 7.9.2 Lifting hook

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, UNLOCK CONT

Description: Signal from control lever to open lock tongue.

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 8 Control system – ATTACH, lifting hook attachment 8:75

Circuit diagram: Circuit 7.9-1

Contact: Signal from S1002 to digital in D790-1/K7:15

Function: 7.1.1 Control levers

Signal value:

1 Input signal active.

0 No signal.

8.4.9.6 ATTACH, menu 6

PRESENT INPUT SIGNALS, LOW SPEED 20/40
Description: Signal from spreading position sensor for end position
DIAG ATTACHMENT 6(X) damping 20'/40' right or left.
PRESENT INPUT SIGNALS
LE RI Circuit diagram: Circuit 5
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or
010080

30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40

Function: 7.5.6 Position sensor spreading

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, 30/35 STOP

Description: Signal from position sensor for end position 30' right or left.

Circuit diagram: Circuit 5

Connection: from inductive sensor B777L to digital in D791/K1:20 or

from inductive sensor B777R to digital in D791/K1:37

Function: 7.5.6 Position sensor spreading

Signal value:

1 Input signal active.

0 No signal.

8.4.9.7 ATTACH, menu 7

PRESENT INPUT SIGNALS, ALIGNMENT LE RI,
UPPER
Description: Signals from sensors alignment right upper and left
DIAG ATTACHMENT 7(X) upper.
PRESENT INPUT SIGNALS
ALIGNMENT LE RI Circuit diagram: Circuit 11B
UPPER X X Contact:
010081

LOWER X X
LE: signal from B7203RU-2 to digital in D791/K1:36
RI: Signal from B7203LU-2 to digital in D791/K1:11

Function: 7.9.2.8 Alignment and detection sensor

Signal value:

1 Input signal active.

0 No signal.

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8:76 8 Control system – ATTACH, lifting hook attachment

PRESENT INPUT SIGNALS, ALIGNMENT LE RI,

LOWER
Description: Signals from sensors alignment right lower and left lower.

Circuit diagram: Circuit 11B

Contact:
LE: signal from B7203LL to digital in D791/K1:27
RI: Signal from B7203RL to digital in D791/K1:26

Function: 7.9.2.8 Alignment and detection sensor

Signal value:

1 Input signal active.

0 No signal.

8.4.9.8 ATTACH, menu 8

PRESENT INPUT SIGNAL LE RI, LOCKED CONT

Description: Signals from sensors locked lock tongue right and left.
DIAG ATTACHMENT 8(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 9
LE RI Contact:
LOCKED CONT X X
LE: signal from B7205LL to digital in D791/K1:23
010082

UNLOCKED CONT X X
RI: Signal from B7205RL to digital in D791/K1:24

Function: 7.9.2.9 Lock tongue sensor

Signal value:

1 Input signal active.

0 No signal.

PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT

Description: Signals from sensors open lock tongue right and left.

Circuit diagram: Circuit 9

Contact:
LE: signal from B7204L to digital in D791-1/K1:22
RI: signal from B7204R to digital in D791-1/K1:41

Function: 7.9.2.9 Lock tongue sensor

Signal value:

1 Input signal active.

0 No signal.

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 8 Control system – ATTACH, lifting hook attachment 8:77

8.4.9.9 ATTACH, menu 9

PRESENT OUTPUT SIGNAL, LOCK CONT

Description: Voltage feed to attachment control valve, locked lock
DIAG ATTACHMENT 9(X) tongues.
PRESENT OUTPUT SIGNAL
LOCK CONT XY Circuit diagram: Circuit 8
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040

010083
Function: 7.4.2 Control valve attachment

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

PRESENT OUTPUT SIGNAL, UNLOCK CONT

Description: Description: Voltage feed to attachment control valve,
open lock tongues.

Circuit diagram: Circuit 8

Connection: digital out from D791/K1:9 to Y6039

Function: 7.4.2 Control valve attachment

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.9.10 ATTACH, menu 10

PRESENT OUTPUT SIGNAL, IND. LOCKED CONT

Description: Voltage feed, indicator light for locked lock tongues -
DIAG ATTACHMENT 10(X) located on carriage.
PRESENT OUTPUT SIGNAL
IND. LOCKED CONT XY Circuit diagram: Circuit 10A
IND. UNLOCKED CONT XY Connection: digital out from D791/K1:29 to H563
010084

IND. ALIGNMENT XY
Function: 7.9.2 Lifting hook

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

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8:78 8 Control system – ATTACH, lifting hook attachment

PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT

Description: Voltage feed, indicator light for open lock tongues -
located on carriage.

Circuit diagram: Circuit 10A

Connection: digital out from D791/K1:25 to H562

Function: 7.9.2 Lifting hook

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

PRESENT OUTPUT SIGNAL, ALIGNMENT

Description: Voltage feed, alignment indicator light - located on
carriage.

Circuit diagram: Circuit 10A

Connection: digital out from D791/K1:39 to H564

Function: 7.9.2 Lifting hook

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short circuit. Short circuiting
can only be detected when the output is active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit
can only be detected when the output signal is missing.

8.4.9.11 ATTACH, menu 11

OUTPUT SIDE SHIFT LE, REFERENCE

Description: Status for control current to attachment control valve
DIAG ATTACHMENT 11(X) for side shift left.
OUTPUT SIDESHIFT LE
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:32 to Y6020/1
010088

FEEDBACK XXX
Function: 7.4.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

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 8 Control system – ATTACH, lifting hook attachment 8:79

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
Connection: output signal reference value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SIDE SHIFT LE, FEEDBACK

Description: Current value for control current to attachment control
valve for side shift left.
Circuit diagram: Circuit 7.4-2
Connection: output signal actual value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.12 ATTACH, menu 12

OUTPUT SIDE SHIFT RI, REFERENCE
Description: Status for control current to attachment control valve
DIAG ATTACHMENT 12(X) for side shift right.
OUTPUT SIDESHIFT RI
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089

FEEDBACK XXX
Function: 7.4.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT RI, REQUIRED VALUE

Description: Reference value for control current to attachment control
valve for output signal, side shift right.
Circuit diagram: Circuit 7.4-2
Connection: output signal reference value out from D791-1/K1:18 to
Y6021/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SIDE SHIFT RI, FEEDBACK

Description: Current value for control current to attachment control
valve for side shift right.
Circuit diagram: Circuit 7.4-2

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8:80 8 Control system – ATTACH, lifting hook attachment

Connection: output signal actual value out from D791-1/K1:18 to

Y6019/2

Function: 7.4.2 Control valve attachment

Signal value: XXX = Measured current value in mA.

8.4.9.13 ATTACH, menu 13

OUTPUT LEVELLING CW, REFERENCE

Description: Status control current to control valve attachment for
DIAG ATTACHMENT 13(X) levelling right.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:31 to Y6035
010085

FEEDBACK XXX
Function: 7.8.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT LEVELLING CW, REQUIRED VALUE

Description: Reference value for control current to attachment control
valve for output signal, levelling right.

Circuit diagram: Circuit 6

Connection: output signal reference value out from D791/K1:19 to

Y6035

Function: 7.8.2 Control valve attachment

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT LEVELLING CW, FEEDBACK

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

Circuit diagram: Circuit 6

Connection: output signal, actual value out from D791/K1:19 to Y6035

Function: 7.8.2 Control valve attachment

Signal value: XXX = Measured current value in mA.

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 8 Control system – ATTACH, lifting hook attachment 8:81

8.4.9.14 ATTACH, menu 14

OUTPUT LEVELLING CCW, REFERENCE

Description: Status control current to control valve attachment for
DIAG ATTACHMENT 14(X) levelling left.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:30 to Y6036

010086
FEEDBACK XXX
Function: 7.8.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT LEVELLING CCW, REQUIRED VALUE

Description: Reference value for control current to attachment control
valve for output signal, levelling left.

Circuit diagram: Circuit 6

Connection: output signal, reference value out from D791/K1:19 to

Y6036

Function: 7.8.2 Control valve attachment

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT LEVELLING CCW, FEEDBACK

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

Circuit diagram: Circuit 6

Connection: output signal, actual value out from D791/K1:19 to Y6036

Function: 7.8.2 Control valve attachment

Signal value: XXX = Measured current value in mA.

8.4.9.15 ATTACH, menu 15

Not used.

DIAG ATTACHMENT 15(X)

NOT USED
010077

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8:82 8 Control system – ATTACH, lifting hook attachment

8.4.9.16 ATTACH, menu 16

Not used.

DIAG ATTACHMENT 16(X)

NOT USED

010078
8.4.9.17 ATTACH, menu 17

OUTPUT SPREAD LE OUT, REFERENCE

Description: Status for control current to attachment control valve
DIAG ATTACHMENT 17(X) for spreading, left side out.
OUTPUT SPREAD LE OUT
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:3 to Y6018L
010087

FEEDBACK XXX
Function: 7.5.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREAD LE OUT, REQUIRED VALUE

Description: Reference value for control current to attachment control
valve for output signal spreading left side out.

Circuit diagram: Circuit 4

Connection: output signal, reference value out from D791/K1:16 to

Y6018L

Function: 7.5.2 Control valve attachment

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREAD LE OUT, FEEDBACK

Description: Current value for control current to attachment control
valve for spreading, left side out.

Circuit diagram: Circuit 4

Connection: output signal, actual value out from D791/K1:16 to Y6018L

Function: 7.5.2 Control valve attachment

Signal value: XXX = Measured current value in mA.

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 8 Control system – ATTACH, lifting hook attachment 8:83

8.4.9.18 ATTACH, menu 18

OUTPUT SPREADER LE IN, REFERENCE

Description: Status for control current to attachment control valve
DIAG ATTACHMENT 18(X) for spreading, left side in.
OUTPUT SPREADER LE IN
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:2 to Y6019L

010090
FEEDBACK XXX
Function: 7.5.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER LE IN, REQUIRED VALUE

Description: Reference value for control current to attachment control
valve for output signal spreading left side in.

Circuit diagram: Circuit 4

Connection: output signal, reference value out from D791/K1:16 to

Y6019L

Function: 7.5.2 Control valve attachment

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREADER LE IN, FEEDBACK

Description: Current value for control current to attachment control
valve for spreading, left side in.

Circuit diagram: Circuit 4

Connection: output signal, actual value out from D791/K1:16 to Y6019L

Function: 7.5.2 Control valve attachment

Signal value: XXX = Measured current value in mA.

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8:84 8 Control system – ATTACH, lifting hook attachment

8.4.9.19 ATTACH, menu 19

OUTPUT SPREAD RI OUT, REFERENCE

Description: Status for control current to attachment control valve for
DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
Circuit diagram: Circuit 4
REFERENCE XY
REQUIRED VALUE XXX Connection: digital out from D791/K1:5 to Y6018R

010091
FEEDBACK XXX
Function: 7.5.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREAD RI OUT, REQUIRED VALUE

Description: Reference value for control current to attachment control
valve for output signal spreading right side out.

Circuit diagram: Circuit 4

Connection: output signal, reference value out from D791/K1:17 to

Y6018R

Function: 7.5.2 Control valve attachment

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREAD RI OUT, FEEDBACK

Description: Current value for control current to attachment control
valve for spreading, right side out.

Circuit diagram: Circuit 4

Connection: output signal, actual value out from D791/K1:17 to

Y6018R

Function: 7.5.2 Control valve attachment

Signal value: XXX = Measured current value in mA.

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 8 Control system – ATTACH, lifting hook attachment 8:85

8.4.9.20 ATTACH, menu 20

OUTPUT SPREADER RI IN, REFERENCE

Description: Status for control current to attachment control valve
DIAG ATTACHMENT 20(X) for spreading, right side in.
OUTPUT SPREADER RI IN
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:4 to Y6019R

010092
FEEDBACK XXX
Function: 7.5.2 Control valve attachment

Signal value:

00 No output signal, PWM off.

10 Output signal active, short circuit.
11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER RI IN, REQUIRED VALUE

Description: Reference value for control current to attachment control
valve for output signal spreading right side in.

Circuit diagram: Circuit 4

Connection: output signal, reference value out from D791/K1:17 to

Y6019R

Function: 7.5.2 Control valve attachment

Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREADER RI IN, FEEDBACK

Description: Current value for control current to attachment control
valve for spreading, right side in.

Circuit diagram: Circuit 4

Connection: output signal, actual value out from D791/K1:17 to

Y6019R

Function: 7.5.2 Control valve attachment

Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 80-100 VDCF05.01GB

8:86 8 Control system – ATTACH, lifting hook attachment

8.4.9.21 ATTACH, menu 21

PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40

DIAG ATTACHMENT 21(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer, automatic spreading 20'-40'.

BUZZER AUTO 20-40 XY Circuit diagram: Circuit 3

009181
Connection: digital out from D791/K1:28 to H9003

Function: 7.5 Spreading

Signal value:

01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK.

8.4.9.22 ATTACH, menu 22

PRESENT INPUT SIGNALS, DETECT UPPER CONT.

Description: Signals from detection sensor for upper container right
DIAG ATTACHMENT 22(X) (B7203 RU) and detection sensor for upper container left (B7203LU).
PRESENT INPUT SIGNALS
DETECT UPPER CONT. Circuit diagram: Circuit 11B
LE RI LE: signal from B7203LU to digital in D791-1/K1:13
010075

X X RI: Signal from B7203RU to digital in D791-1/K1:21

Function: 7.9.2.8 Alignment and detection sensor

Signal value:

1 Input signal active.

0 No signal.

8.4.9.23 ATTACH, menu 23

PRESENT OUTPUT SIGNAL, IND. UPPER ALIGNMENT

Description: Signals from sensors alignment right upper (B7203RU-2)
DIAG ATTACHMENT 23(X) and left upper (B7203LU-2).
PRESENT OUTPUT SIGNAL
IND. UPPER Circuit diagram: Circuit 11B
ALIGNMENT XY Contact:
010076

LE: signal from B7203LU-2 to digital in D791-1/K1:11

RI: Signal from B7203RU-2 to digital in D791-1/K1:36

Function: 7.9.2.8 Alignment and detection sensor

Signal value:

1 Input signal active.

0 No signal.

VDCF05.01GB Workshop Manual DCF 80-100

 8 Control system – ATTACH, twistlock attachment 8:87

8.4.9 ATTACH, twistlock attachment

ATTACH, description
This group covers attachment functions.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH

005339
OLS EXTRA

8.4.9.1 ATTACH, menu 1

PRESENT INPUT SIGNALS, P3

Description: Signal from control lever P3.
DIAG ATTACHMENT 1(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit 7.0-1, 7.0-2
P3 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in
P4 XX.XXV D790-1/K7:5
005416

P7 XX.XXV
Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P4

Description: Signal from control lever P4.

Circuit diagram: Circuit 7.0-1, 7.0-2

Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6

Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P7

Description: Signal from control lever P7.

Circuit diagram: Circuit 7.0-1

Connection: signal from R8075-2/3 to analogue in D790-1/K9:9

Function: 7.1.1 Control levers

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.