Kalmar DRF 450 Load Handling

7 Load handling 1
7 Load handling
Table of Contents 7 Loadhandling

mm mm mm mm mm mm
7 Load handling................................................................................................. 5
7.1 Controls and instrumentation ..................................................................... 7
7.1.1 Control lever .......................................................................................... 7
7.1.2 Switch lock twistlocks ............................................................................ 9
7.1.3 Switch automatic spreading ................................................................... 9
7.1.5 Switch stop at 30' or 35' ....................................................................... 10
7.2 Lifting/lowering ......................................................................................... 11
7.2.1 Hydraulic oil pump ............................................................................... 14
7.2.2 Servo filter ............................................................................................ 15
7.2.3 Pressure reducer ................................................................................. 15
7.2.4 Accumulator servo circuit ..................................................................... 17
7.2.5 Manoeuvre valve lift, lower, protrude ................................................... 19
7.2.6 Shuttle valve ........................................................................................ 20
7.2.7 Valve block lift cylinder ........................................................................ 21
7.2.8 Lift cylinder ........................................................................................... 24
7.2.9 Sensor hydraulic pressure lift cylinder ................................................. 28
7.2.10 Lift boom .............................................................................................. 30
7.2.11 Sensor boom angle .............................................................................. 30
7.2.12 Pipes and hoses .................................................................................. 31
7.3 Protruding ................................................................................................. 32
7.3.2 Servo filter ............................................................................................ 35
7.3.3 Pressure reducer ................................................................................. 36
7.3.4 Accumulator servo circuit ..................................................................... 36
7.3.5 Manoeuvre valve lift, lower, protrude ................................................... 36
7.3.6 Shuttle valve ........................................................................................ 36
7.3.7 Valve block protrude cylinder ............................................................... 37
7.3.8 Extension cylinder ................................................................................ 37
7.3.9 Valve block pump unloading ................................................................ 40
7.3.10 Lift boom .............................................................................................. 41
7.3.11 Sensor boom length ............................................................................. 43
7.3.12 Pipes and hoses .................................................................................. 43
7.4 Side-shift .................................................................................................. 44
7.4.2 Valve block top lift hydraulics ............................................................... 46
7.4.3 Control valve attachment ..................................................................... 47
7.4.4 Shuttle valve ........................................................................................ 52
7.4.5 Sideshift cylinder .................................................................................. 52
7.4.6 Sideshift frame ..................................................................................... 53
7.4.7 Main beam attachment ........................................................................ 56
7.4.8 Unloading valve attachment ................................................................ 57
7.4.9 Pipes and hoses .................................................................................. 57
7.5 Positioning ................................................................................................ 58
Workshop manual DRF 400–450 VDRF03.01GB

2 7 Load handling

7.5.3 Control valve attachment ...................................................................... 64
7.5.4 Shuttle valve ......................................................................................... 64
7.5.5 Valve block positioning motor ............................................................... 65
7.5.6 Positioning motor .................................................................................. 65
7.5.7 Positioning chains ................................................................................ 68
7.5.8 Positioning beam .................................................................................. 75
7.5.9 Main beam attachment ......................................................................... 77
7.5.10 Position sensor positioning ................................................................... 78
7.5.11 Unloading valve attachment ................................................................. 78
7.5.12 Pipes and hoses ................................................................................... 78
7.5.13 Summer automatic positioning 20'-40' ................................................. 79
7.6 Rotation ..................................................................................................... 80
7.6.1 Hydraulic oil pump ................................................................................ 83
7.6.3 Control valve attachment ...................................................................... 84
7.6.4 Shuttle valve ......................................................................................... 85
7.6.5 Valve block rotation motor .................................................................... 85
7.6.6 Rotation motor unit ............................................................................... 86
7.6.7 Rotation yoke ....................................................................................... 88
7.6.8 Ring gear .............................................................................................. 91
7.6.9 Sideshift frame ..................................................................................... 92
7.6.10 Sensor rotation stop ............................................................................. 93
7.6.11 Unloading valve attachment ................................................................. 93
7.6.12 Pipes and hoses ................................................................................... 93
7.7 Tilt ............................................................................................................. 94
7.7.1 Hydraulic oil pump ................................................................................ 99
7.7.3 Damping block tilt ............................................................................... 100
7.7.4 Lock valve tilt ...................................................................................... 102
7.7.5 Control valve attachment .................................................................... 102
7.7.6 Shuttle valve ....................................................................................... 103
7.7.7 Tilt cylinder ......................................................................................... 103
7.7.8 Lift boom ............................................................................................. 103
7.7.9 Rotation yoke ..................................................................................... 103
7.7.10 Unloading valve attachment ............................................................... 103
7.7.11 Pipes and hoses ................................................................................. 103
7.8 Levelling .................................................................................................. 104
7.8.1 Hydraulic oil pump .............................................................................. 108
7.8.2 Valve block top lift hydraulics ............................................................. 108
7.8.3 Control valve attachment .................................................................... 108
7.8.4 Shuttle valve ....................................................................................... 109
7.8.5 Over-centre valve levelling ................................................................. 109
7.8.6 Valve block levelling cylinders ............................................................ 110
7.8.7 Levelling cylinders .............................................................................. 110
7.8.8 Sideshift frame ................................................................................... 111
7.8.9 Unloading valve attachment ............................................................... 111
VDRF03.01GB Workshop manual DRF 400–450

7 Load handling 3
7.8.10 Pipes and hoses ................................................................................ 111

7.9 Load carrying .......................................................................................... 112
7.9.1 Twistlocks .......................................................................................... 112
7.9.2 Lift legs .............................................................................................. 124
7.10 Additional functions ................................................................................ 153
7.10.1 Support jacks ..................................................................................... 153
7.10.2 Weight indicator ................................................................................. 161
7.10.3 Container counter .............................................................................. 167
7.10.4 Synchronous lift ................................................................................. 171

4 7 Load handling

7 Load handling – 7 Load handling 5
7 Load handling
mm mm mm mm mm mm
Position sensor, checking and

page
–
adjustment
1
2
4
3
3
5 6 7 8
9 12, 13 11
11
10
14
15
16
008212
1. Sensor, boom length 5. Sensor, twistlocks 13. Sensor, clamping position

9. Sensor, support jacks up
6. Sensor, spreading 10. Sensor, support jacks down 14. Sensor, knee
2. Sensor, rotation stop
3. Sensor, alignment 7. Sensor, damping 11. Sensor, lift leg

15. Sensor, lowered cab
end position

6 7 Load handling – 7 Load handling
4. Sensor, steering angle 8. Sensor, steering 12. Sensor, alignment 16. Sensor Overheight-legs up
axle
1 Machine in service position, see tab B Safety.

2 Check that the sensor in question is free of damage and dirt.
C-C
4±1 mm
3 Check that the distance between position sensor and indicator is
4±1 mm. Adjust as needed.
C-C
4±1 mm
I M P OR TA NT
008209
It is very important that the bolt head by Sensor steer-
4±1 mm ing axle is directly opposite the sensor's centre and
Adjusting position sensor - indicator that the bolt head faces so that the edge is parallel
with the sensor's top.

7 Load handling – 7.1 Controls and instrumentation 7
7.1 Controls and instrumentation

7.1.1 Control lever
Control lever, description
page
–
Control lever (S815) is used to control the boom and attachment. The
lever sends voltage signals to Control unit cab (D790-1).
1 2 The control lever has three or four potentiometer-controlled functions
3
and six on/off functions.
4
Lift and lower
5 Lift and lower is controlled by moving the control lever forward (lower
7 boom) or back (lift boom). See Lift and lower, function description page
6 11.
The signal can be checked from the diagnostic menu, see section 8
8 Control and monitoring system, group 8.4.8.1 BOOM, menu 1.
Extension
Extension is controlled by moving the control lever right (boom out) or
000442
left (boom in). See Extension, function description page 32.

1. Tilt lock (S815-T3.1) Control and monitoring system, group 8.4.8.1 BOOM, menu 1.
2. Levelling lock (S815-T3.2)
3. Rotation (S815-P3) Sideshift or Spreading
4. Sideshift right (S815-T1.2) When switch (position 4) is pressed down, sideshift right is activated,
5. Sideshift left (S815-T1.1) and when switch (position 5) is pressed down, sideshift left is activat-
6. Opening of twistlocks (S815-T2) at full alignment ed. See Sideshift, function description page 44.
7. Tilt (S815-P4) If the pistol trigger (position 8) is pressed in at the same time as side-
shift right (position 4), then spreader out is activated. If the pistol trig-
8. Pistol trigger (S815-T4): Activates weighing ,
ger(position 8) is pressed in at the same time as sideshift left (position
changes sideshift function to spreader out (S815-
5) then spreader in is activated. See Spreading, function description
T1.2) and spreader in(S815-T1.1) as well as lift to syn-
page 58.
chronised lift
Control and monitoring system, group 8.4.9.2 ATTACH, menu 2.
Rotation
When the potentiometer (position 3) is pressed down on the left side,
then rotation clockwise is activated, and rotation counter-clockwise is
activated when the right side is pressed down. See Rotation, function
description page 80.
Opening of twistlocks
When the switch (position 6) is activated, the twistlocks are opened, if
the conditions for this are fulfilled. See Twistlocks, function description
page 112.

8 7 Load handling – 7.1.1 Control lever
Tilt
When the potentiometer (position 7) is pressed down at the top edge,

then tilt out is activated, and tilt in is activated when the switch is
pressed in at the bottom edge. See Tilt control, function description
page 97.
Tilt lock
When the switch (position 1) is pressed down, then tilt lock is activat-
ed. When tilt lock is activated, the light in the switch is on. See Tilt lock,
function description page 95.
Levelling
When the potentiometer rotation (position 3) is pressed down on the

left side at the same time as the pistol trigger (position 8) is pressed in,
then levelling right is activated. When the right side is pressed down at
the same time as the pistol trigger is pressed in, then levelling left is
activated. See Hydraulic levelling, function description page 104.
Levelling lock
When switch (position 2) is pressed down, levelling lock is activated.

When levelling lock is activated, the indicator light in the switch is on.
See Levelling lock, function description page 106.
Pistol trigger
The pistol trigger (position 8) activates weighing if the machine is

equipped with weight indicator. See Weight indicator, description page
161.
The pistol trigger also changes the function of other buttons on the
control lever.
If sideshift is activated at the same time as the pistol trigger is pressed
in, then spreading is activated. See Spreading, function description
page 58.

7 Load handling – 7.1.2 Switch lock twistlocks 9
If lift is activated at the same time as the pistol trigger is pressed

in, then synchronized lift is activated, if the machine is equipped with
this option. See Synchronous lift, function description page 171.
7.1.2 Switch lock twistlocks

Switch lock twistlocks, description
page
–
Switch lock twistlocks (S1001) controls locking of twistlocks. The

switch has three positions: two fixed and one rocker with the following
functions.
1. Automatic locking of the twistlocks at full alignment and released
parking brake.
2. Twistlocks open (off).
3. Manual locking of the twistlocks at full alignment and released
parking brake (sprung).
000443
Twistlocks are opened with a switch on the control lever, see Control
lever, description page 7.
The switch is supplied with voltage from and sends a voltage signal to
Control unit cab (D790-1).
7.1.3 Switch automatic spreading

Switch automatic spreading, description
page
–
Switch automatic spreading (S1012) activates automatic spreading.

When the switch is pressed down spreading automatically goes to
next position (20, 30 or 40 foot) if spreading is activated with the con-
trol lever.
The switch is supplied with voltage from and sends a voltage signal to
Control unit cab (D790-1) when the switch is activated.
000444

10 7 Load handling – 7.1.5 Switch stop at 30' or 35'
7.1.5 Switch stop at 30' or 35'

Switch stop at 30’ or 35’, description
page
–
Switch stop at 30’ or 35’ (S1004) activates 30 and 35 foot stop. When
the switch is pressed down the spreading function changes from 20’–
40’ to stop at 30’.
35
30- The switch is supplied with voltage from and sends a voltage signal to
The signal can be checked with from the menu, see section 8 Control
and monitoring system, group 8.4.9.2 ATTACH, menu 2.
000447

7 Load handling – 7.2 Lifting/lowering 11
7.2 Lifting/lowering
Lift and lower, function description
page
–
Condition Reference value Reference

Control switch Disengaged Tab 11 Common electric, group 11.5.1.4 Ma-
noeuvre switch voltage
Twistlocks Locked or unlocked, not intermediate position Twistlocks, description page 119
Overload system Boom up: passive Section 8 Control and monitoring system,
Boom down: passive or by-pass activated group 8.2.1 Overload system
Alignment Boom down: no alignment Twistlocks, function description page 112
By-passed or boom height lower than height limita- Tab 8 Control system, group 8.2.4 Height limi-
tion tation
Height limitation
D1
1
2, 4 5
D790-1 D794
D797-F D797-R 13, 18

3 D22
D18
D3
D17 >˚
6 6 22
11 C10 D13 14 19
12
PSS PSL
10 PP C-M Pa 16, 21
A1 VA
C-
P B1 T
C+
LS D
8 Pa
7 C+M
17
C9 15, 20
9
006405

12 7 Load handling – 7.2 Lifting/lowering
Pos Explanation Signal description Reference

1 Control lever (S815-P1) sends voltage Lower: US815/P1 = 0.5–2.0 V Control lever, description page 7
signal proportional to lever movement D1: Diagnostic menu, see tab 8 Control
Zero position: US815/P1 =
to Control unit cab (D790-1). system, group 8.4.8.1 BOOM, menu 1
2.0–3.0 V
Lift: US815/P1 = 3.0–4.5 V
0.5 V is the fastest lowering

speed and 4.5 V is the fast-
est lift speed. Lower voltag-
es than 0.5 V and higher
voltages than 4.5 V are used
to detect malfunctions in ca-
bling and controls.
2 Control unit cab (D790-1) sends re- Controlled by control and Tab 11 Common electric, group 11.5.3.1
quest for Boom up or Boom down with monitoring system, error Control unit cab
speed information on CAN-bus. shown with error code.
3 Control unit frame front (D797-F) acti- I = 380–650 mA Tab 11 Common electric, group 11.5.3.2
vates Servo valve, lift (Y6005) or Servo Control unit frame front
valve, lower (Y6004). D3: Diagnostic menu, see tab 8 Control
system, group 8.4.8.4 BOOM, menu 4 and
8.4.8.5 BOOM, menu 5
4 Control unit cab (D790-1) sends re- Controlled by control and Tab 11 Common electric, group 11.5.3.1
quest for increased engine rpm on monitoring system, error Control unit cab
CAN-bus shown with error code.
5 Control unit engine (D794) increases Controlled by control and Tab 11 Common electric, group 11.5.3.10
engine rpm. monitoring system, error Control unit engine
shown with error code.
6 Servo valve, lift (Y6004) or Servo - Control valve lift lower and extension, de-
valve, lower (Y6005) pressurizes con- scription page 19
trol valve's lift spool with servo pres- D3: Diagnostic menu, see tab 8 Control
sure. system, group 8.4.8.4 BOOM, menu 4 and
8.4.8.5 BOOM, menu 5
7 The control valve's lift spool changes - Control valve lift lower and extension, de-
position and pressurizes valve block lift scription page 19
cylinder and sends load signal to the
hydraulic oil pumps.
8 The shuttle valve sends the strongest - Tab 10 Common hydraulics, group 10.5.3
load signal if several functions are acti- Shuttle valve
vated simultaneously.
9 The hydraulic oil pumps pump oil from See pressure plate on left Tab 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. frame beam. Axial piston pump with variable displace-
ment
10 The pressure reducer reduces the oil See pressure plate on left Pressure reducer, description page 15
pressure from the hydraulic oil pumps frame beam.
to servo pressure for the control valve.

7 Load handling – 7.2 Lifting/lowering 13

11 The accumulator stores servo pres- See pressure plate on left Accumulator servo circuit, description
sure. The non-return valve in the pres- frame beam. page 17
sure reducer makes it possible to store
the pressure when the engine is shut
off.
12 The servo filter cleans the servo oil be- - Servo filter, description page 15
fore the control valve.
13 At boom down Control unit frame front U = 24 V Tab 11 Common electric, group 11.5.3.2
(D797-F) activates Servo valve, block- Control unit frame front
ing right (Y6001) and Servo valve, D13: Diagnostic menu, see tab 8 Control
blocking left (Y6002). system, group 8.4.8.2 BOOM, menu 2
14 For boom down, Servo valve, blocking - Valve block lift cylinder, description page
right (Y6001) and Servo valve, block- 21
ing left (Y6002) affect the blocking D13: Diagnostic menu, see tab 8 Control
valves in the valve blocks for left and system, group 8.4.8.2 BOOM, menu 2
right lift cylinder, respectively.
15 For boom up, the blocking valves are - Valve block lift cylinder, description page
opened in the valve blocks for left and 21
right lift cylinder, respectively, by the
hydraulic pressure from the control
valve.
For boom down, the blocking valve
opens and releases pressure from the
lift cylinder.
16 The lift cylinders' piston side are pres- - Lift cylinder, description page 24
surized and the boom lifts.
17 Regeneration UB768-L1/1 = 5 V Sensor hydraulic pressure lift cylinder, de-

Sensor hydraulic pressure lift cylinder scription page 28
UB768-L1/2 = 0 V
piston side left (B768-L1) sends volt- D17: Diagnostic menu, see tab 8 Control
UB768-L1/5 = 0.5-4.5 V
age signal proportional to oil pressure system, group 8.4.10.3 OP, menu 3
to Control unit frame front (D797-F). Regeneration is activated
when the pressure in the lift
NOTE cylinders is 8.5 MPa, regen-
eration is interrupted if the
Regeneration is not possible near
pressure reaches 18.5 MPa.
end-position or at overload.
18 Control unit frame front (D797-F) acti- U = 24 V Tab 11 Common electric, group 11.5.3.2
vates Solenoid valve regeneration right Control unit frame front
(Y6051) and Solenoid valve regenera- D18: Diagnostic menu, see tab 8 Control
tion left (Y6052) if the pressure is suffi- system, group 8.4.8.3 BOOM, menu 3
ciently low for regeneration.
19 Servo valve, regeneration pressurizes - Valve block lift cylinder, description page
the regeneration valve. 21
20 The regeneration valve changes posi- - Valve block lift cylinder, description page
tion and leads oil from the lift cylinder's 21
rod side to the piston side.

14 7 Load handling – 7.2.1 Hydraulic oil pump

21 Lift speed increases. - -
22 Damping - Tab 8 Control system, group 8.2.1.5 Sen-

When the boom is approx. 4° from any sor boom angle
end-position, then damping is activat- Tab 11 Common electric, group 11.5.3.3
ed. Control unit frame rear
Sensor boom angle (B771) sends volt- D22: Diagnostic menu, see tab 8 Control
age signal proportional to boom angle system, group 8.4.8.8 BOOM, menu 8
to Control unit frame rear (D797-R)
which request damping on the CAN-
bus.
Hydraulic diagram basic machine
Lowering speed, checking

page
–
D ANGER
The lowering speed must be correct. If lowering
speed is too high, there is a risk of tipping over.
The machine may absolutely not be used before the

lowering speed is verified.
1 Operate and warm up the machine and hydraulics until the hy-
draulic oil has reached operating temperature 50 °C.
2 Lift a container that weighs 35-45 tons.
3 Drive the machine aside to a level and safe place.
NOTE
It is important that the ground surface is level and does not
slope.
4 Run in the boom completely and lift max.
5 Measure the time it takes to lower from top position until the con-
tainer is approx. 20 cm from the ground.
Lowering should take 18-21 seconds.
6 If the time is incorrect, contact Kalmar Industries for further in-
structions.
7.2.1 Hydraulic oil pump

Hydraulic oil pump, general
page
–
See section 10 Common hydraulics, group 10.4.2 Axial piston pump

with variable displacement.

7 Load handling – 7.2.2 Servo filter 15
7.2.2 Servo filter

Servo filter, description
page
–
The servo filter protects the control valve's servo circuits against impu-
rities. The servo filter is located in the front edge of the lift beam on the
right-hand side in the engine bay, between the pressure reducer and
control valve lift, lower and extension.
The servo filter is a low pressure filter with detachable filter cartridge.
The oil is cleaned when it passes through the filter cartridge filter ma-
terial.
The filter cartridge is pressed against the upper section of the filter
housing by a spring. Rubber gaskets seal between cartridge and filter
housing. If the back pressure through the filter is too great the cartridge
is pressed down so that the oil passes through the cartridge. This oc-
curs if the oil is viscous (cold or incorrect viscosity) or if the filter car-
tridge is clogged.
000534
7.2.3 Pressure reducer

Pressure reducer, description
page
–
The pressure reducer reduces the pressure from the hydraulic oil
pumps to servo pressure for the control valve. The pressure reducer
1 is located to the right on the lift beam in the engine compartment with
7 the accumulator for servo pressure.
2 Servo pressure is stored in an accumulator. A built-in non-return valve

6 prevents pressure leakage from the accumulator when the machine is
not used.
5
3
000432
1. Accumulator servo pressure

2. Pressure check connection, servo pressure
3. Pressure supply from servo filter
4. Return to tank
5. Servo pressure to control valve
6. Adjusting screw, servo pressure.

16 7 Load handling – 7.2.3 Pressure reducer
Servo pressure, checking and adjusting

page
–
NOTE
Read the instructions for oil before working, see tab B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at

operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
˚C 2 Machine in service position, see tab B Safety.

3 Depressurise the brake and hydraulic systems, see tab B Safety.
˚C
Operating menu hydraulic oil temperature 000475
4 Connect a pressure gauge (0–25 MPa) to the test outlet on the

pressure reducer.
5 Start the engine and check the servo pressure. Compare with the
pressure plate.
MPa Turn the steering wheel or activate a load handling function to ac-
tivate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
MPa
MPa
MPa MPa MPa

MPa
MPa
MPa MPa
001029
920643.0024

7 Load handling – 7.2.4 Accumulator servo circuit 17
6 If needed, adjust the pressure with the adjusting screw. Loosen

the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function
must be activated so that servo pressure is used from the
accumulator for a reduction on the adjusting screw to be
seen on the pressure gauge. Sometimes the engine has to
be shut off between the checks.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
8 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
7.2.4 Accumulator servo circuit

Accumulator servo circuit, description
page
–
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating the control valve's functions. The accumulator
is located on the pressure reducer to the right of the lift beam in the
engine bay.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitro-
gen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
001095

18 7 Load handling – 7.2.4 Accumulator servo circuit
Accumulator servo circuit, replacement

page
–
NOTE
Read the safety instructions for oil before working, see tab B
Safety.
1 Depressurize the brake and hydraulic systems, see tab 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 Load handling – 7.2.5 Manoeuvre valve lift, lower, protrude 19
7.2.5 Manoeuvre valve lift, lower, protrude

Control valve lift lower and extension, description
page
–
The control valve controls the speed and direction of lift and extension.
9 The control valve is located on a bracket in the space between the lift
beam and front axle.
8 The valve has two sections: one for the lift function and one for boom
extension. The sections have great similarities but are described sep-
7 1
arately for each function. For extension, see Control valve lift, lower
and extension, description page 36. Electric servo valves control the
6 2 flow from the valve.
5 The control valve is a proportion valve controlled by servo valves. This
3 means that both size and direction of flow from the valve can be ad-
justed and that the valve also sends a control signal to the variable
4 pumps.
Electrically controlled pressure reducing valves (servo valves) convert
electrical current to a small hydraulic pressure proportional to the cur-
rent, so-called "servo pressure". The servo pressure acts on spring
centred control slides in the control valve for the function in question
and this way control the main flow.
The speed of the function is controlled by means of the flow being reg-
ulated in proportion to the lever movement.
000529
1. Servo valve boom out (Y6006) Lift slide

2. Servo valve boom in (Y6007) The lift slide controls direction and flow of oil to the lift cylinder.
3. Servo valve lower (Y6004)
4. Servo valve lift (Y6005) Servo valve lift
5. Connection, rod side, right lift cylinder (B2) Servo valve lift controls servo pressure to the lift slide so that this con-
6. Connection, piston side, right lift cylinder (A1) trols oil pressure for lift. The valve is controlled electrically with Sole-
7. Connection, feed from hydraulic oil pumps (P) noid valve lift (Y6005) which is activated by Control unit frame front
8. Connection, rod side, extension cylinder (B1) (D797-F).
9. Connection, piston side, extension cylinder (A1)
The signals can be checked from the diagnostic menu, see section 8
Control and monitoring system, group 8.4.8.4 BOOM, menu 4.
Servo valve lower

Servo valve lower controls servo pressure to the lift slide so that it con-
trols oil pressure for lowering. The valve is controlled electrically with
Solenoid valve lower (Y6004) which is activated by Control unit frame
front (D797-F).

20 7 Load handling – 7.2.6 Shuttle valve
Control valve lift, lower, and extension, changing

page
–
D ANGER
The lowering speed must be correct. If lowering
speed is too high, there is a risk of tipping over.
The machine may absolutely not be used before the

lowering speed is verified.
After changing Control valve lift, lower and extension, or parts of the
valve, the lowering speed must be checked. See Lowering speed,
checking page 14.
7.2.6 Shuttle valve

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

7 Load handling – 7.2.7 Valve block lift cylinder 21
7.2.7 Valve block lift cylinder

Valve block lift cylinder, description
page
–
Valve block lift cylinder directs the oil to the lift cylinder and is bolted
1
directly on the lower part of the lift cylinder. The valve block contains
2 a blocking valve, regeneration valve, non-return valve and shock
valve.
3
Blocking valve
4 The blocking valve prevents unwanted lowering and angling of the lift
cylinders. The blocking valve holds the load by ensuring that the con-
5
nection to the lift cylinder's piston side is closed. (The pressure passes
6 through a restriction as blocking pressure and holds the valve slide
closed.)
9
7 Servo valve blocking affects the blocking valve. The servo valve is
controlled electrically with Solenoid valve, blocking left (Y6002) and
8
Solenoid valve, blocking right (Y6001), which are activated by Control
unit frame front (D797-F).
Regeneration valve
The regeneration valve directs oil from the cylinder's rod side back to
the piston side. This makes it possible to re-use the oil for lifting. For
000473
more information on regeneration, see Lift and lower, function descrip-

tion page 11. The regeneration valve is controlled by servo valve re-
1. Connection, rod side, lift cylinder (C-) generation.
2. Servo valve, regeneration (Y6051 or Y6052)
Servo valve for regeneration actuates the regeneration valve. The ser-
3. Connection, pressure supply (VA)
vo valve is controlled electrically with Solenoid valve, regeneration
4. Connection tank (T)
right (Y6051) and Solenoid valve, regeneration left (Y6052), which are
5. Pressure sensor, piston side (C+M)
activated by Control unit frame front (D797-F).
6. Drain servo valves (D)
7. Shock valve The signal can be checked from the diagnostic menu, see section 8
8. Servo valve, blocking (Y6001 or Y6002) Control and monitoring system, group 8.4.8.3 BOOM, menu 3.
9. Pressure sensor, rod side (C-M)
Shock valve
The shock valve protects the hydraulic system against surges which
can occur when operating with a load. The shock valve opens a con-
nection between the lift cylinder piston side and tank if the pressure
becomes too high.
Non-return valve
The non-return valve prevents oil from flowing the wrong way during
regeneration.

22 7 Load handling – 7.2.7 Valve block lift cylinder
Valve block lift cylinder, replacement

page
–
NOTE
Safety.
3 Turn the start key to position 0 and turn off the main electric pow-
er.
4 Mark up and detach the wiring from the valve block.
5 Remove the cabling's clamping at the valve block.
6 Mark up and detach the hydraulic hoses from the valve block.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.

7 Load handling – 7.2.7 Valve block lift cylinder 23
7 Remove the valve block from the lift cylinder.

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

with the marking.
NOTE

24 7 Load handling – 7.2.8 Lift cylinder
11 Connect the wiring to the valve block in accordance with the

marking.
12 Clamp the cable harness as before.
13 Turn on the main electric power and start the engine.
14 Activate lift carefully.
C AUTION
Air in the hydraulic system may cavitate and can re-
sult in product damage.
Activate the functions carefully and operate at the

lowest possible speed a couple of times to avoid cav-
itation.
15 Check for leaks.

16 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be at the top of the level glass. Top up as needed.
C AUTION
Overfilling of oil.
Leakage and environmental damage.
The hydraulic oil level is checked with the boom com-

pletely lowered and retracted.
17 Check the lowering speed, see Lowering speed, checking page

14.
7.2.8 Lift cylinder

Lift cylinder, description
page
–
The lift cylinders lift and lower (angle) the lift boom. The lift cylinders
are located between boom and frame in the front edge of the machine,
one on the right and one on the left-hand side.
On each lift cylinder is a valve block which controls pressurising and
regeneration of the lift cylinder.
The lift cylinder is equipped with pivot bearings both in the cylinder and
the piston rod bracket. The piston rod bracket is threaded in the piston
rod and locked with a lock nut.
The lift cylinders are connected in parallel and fed from control valve
lift, lower and extension, see Control valve lift lower and extension, de-
scription page 19.
001096

7 Load handling – 7.2.8 Lift cylinder 25
Lift cylinder, changing

page
–
D ANGER
Fatal danger, risk of crushing!
Be certain to compensate for the lift cylinder's carry-

ing of the boom by lifting the boom's leading edge
with the lifting equipment.
A lift cylinder weighs approx. 2 tons. Use wooden

blocks as protection between the cab and lift cylinder
when the lift cylinder is lowered or lifted.
The boom may move when the pins are removed.

Make sure that the pins are relieved. Stand to the side
of the boom attachment so that the boom attachment
gives protection in case of any movement.
1 Place the cab in the forward position.

3 Depressurize the hydraulic and brake systems, tab B Safety.
4 Turn the start key to position 0 and turn off the main electrical
power.
5 Connect lifting equipment at the leading edge of the boom.
6 Lift the boom at the leading edge so that the bearings on the lift
cylinders are relieved.

26 7 Load handling – 7.2.8 Lift cylinder
7 Mark up and disconnect the hydraulic hoses from the lift cylinder.
8 Connect lifting equipment to the lift cylinder.
9 Remove the upper pin for the lift cylinder.

10 Relieve the lower bearing on the lift cylinder.
11 Remove the lower pin for the lift cylinder.
12 Lift away the lift cylinder.
13 Install new bearing races in the lift cylinder.
14 Lubricate the lift cylinder's bearing races as well as the holes for
the pins in the frame and boom thoroughly with aluminium paste.
NOTE
The bearings are only lubricated when they are changed.
15 Lift the new lift cylinder into place
16 Install the pins for the lift cylinder.

7 Load handling – 7.2.8 Lift cylinder 27
17 Connect the hydraulic hoses to the lift cylinder.

18 Carefully activate the lift function.
C AUTION

itation.
19 Check for leaks.

C AUTION
Overfilling of oil.

21 Check the lowering speed, see Lowering speed, checking page

14.
Hydraulic cylinders, repairing

page
–
See tab 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

28 7 Load handling – 7.2.9 Sensor hydraulic pressure lift cylinder
7.2.9 Sensor hydraulic pressure lift

cylinder
Sensor hydraulic pressure lift cylinder, description
page
–
Sensor hydraulic pressure lift cylinder measures the pressure in the lift
cylinders and is located on valve block lift cylinder.
The pressure is measured to decide if regeneration can be engaged.
A sensor measures the pressure on the piston side of the left lift cylin-
der.
If the machine is equipped with the option fixed scale an extra pres-
sure sensor is used, on the piston side for the right lift cylinder.
2 1
Of the machine is equipped with the option electric dynamic scale,

then two pressure sensors are used, one for the piston rid side and
one for the piston side on the right and left lift cylinder, respectively (a
total of four sensors).
The sensors are supplied with voltage from and send a voltage signal
proportional to hydraulic oil pressure to Control unit frame front (D797-
F).
001097
Control and monitoring system, group 8.4.10.3 OP, menu 3.
1. Sensor hydraulic pressure lift cylinder piston side
left (B768-L1)
Sensor hydraulic pressure lift cylinder piston side
right (B768-R1)
2. Sensor hydraulic pressure lift cylinder piston
rod side left (B768-L2)
Sensor hydraulic pressure lift cylinder piston rod
side right (B768-R2)
Sensor, hydraulic pressure, lift cylinder, replace

page
–
NOTE
Safety.
3 Detach the wiring from the lift cylinder hydraulic pressure sensor.
4 Remove the lift cylinder hydraulic pressure sensor.
NOTE
5 Fit a new sensor.
NOTE

7 Load handling – 7.2.9 Sensor hydraulic pressure lift cylinder 29

6 Connect the wiring to the hydraulic pressure sensor.
7 Clamp the cable harness as before.
9 Activate lift carefully.
C AUTION

itation.
10 Check that the valve block's hydraulic connections are sealed

and that lift and lower function correctly.
C AUTION
Overfilling of oil.

12 Check the function of the sensor with diagnostic menu. See tab 8
DIAG OP 3(x) Control system, group 8.4.10.3 OP, menu 3.
PRESENT INPUT SIGNAL
LIFT CYL LE RI Raise the boom and check that the sensor sends values. The val-
C- X.XXV X.XXV ue should be approx. the same as from the sensor on the other
C+ X.XXV X.XXV lift cylinder (RI/LE).
C-
C+
008213

30 7 Load handling – 7.2.10 Lift boom
7.2.10 Lift boom

Lift boom, description
page
–
The lift boom lifts the load. The rear section of the boom is secured into
the frame with two bearing-mounted shafts. In the front edge is a lift
attachment and in the centre on each side of the boom are lift cylinders
which are secured with bearing-mounted shafts. The lift cylinders an-
gle the boom and raise the front section of the boom in this way. The
lift boom is available in several versions depending on reach and load
capacity.
The boom consists of outer boom and inner boom manufactured in
high-strength steel with a minimum number of welds to provide maxi-
mum strength.
The inner boom runs in the outer boom and can be extended longitu-
dinally with the extension cylinder. There are slide plates between in-
ner boom and outer boom which reduce the friction between them.
The slide plates are located in the front edge of the outer boom and
the rear edge of the inner boom.
Running along the left-hand side is a cable chain for hydraulic hoses
and cables between outer and inner boom.
1 2
001239
9 8 7 8 6 5 4 3
1. Outer boom 4. Mounting attachment 7. Lift cylinder
2. Inner boom 5. Tilt cylinder, left side 8. Mounting, lift cylinder
3. Tilt cylinder, right side 6. Extension cylinder 9. Rear boom mounting
7.2.11 Sensor boom angle

Sensor boom angle, general
page
–
See section 8 Control and monitoring system, group 8.2.1.5 Sensor

boom angle.

7 Load handling – 7.2.12 Pipes and hoses 31
7.2.12 Pipes and hoses

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

32 7 Load handling – 7.3 Protruding
7.3 Protruding
Extension, function description
page
–

Control switch Disengaged Tab 11 Common electric, group 11.5.1.4 Manoeuvre switch
voltage
Overload system Boom out: passive Section 8 Control and monitoring system, group 8.2.1 Overload
system
By-passed or attachment within Tab 8 Control system, group 8.2.3 Load centre limitation
limit for load centre limitation.
Load centre limitation
By-passed or boom height low- Tab 8 Control system, group 8.2.4 Height limitation
er than height limitation
Height limitation
1
D1
2, 4 5
D790-1 D794
Pa 18
D797-F D797-R
3,19 14, 20 D18 D24
D20
6 6 D6 D14 15 21 m
12
C11 13
7 PS PL 24
11 PP A1 VA
16, 22
A1 VA
C- 17, 23
P B1 VB C+
LS D
8
D3
9
C10
10
006406

7 Load handling – 7.3 Protruding 33

1 Control lever (S815-P2) sends Boom in: US815/P2 = 0.5–2.0 V Control lever, description page 7
voltage signal proportional to le- D1: Diagnostic menu, see tab 8 Control
Zero position: US815/P2 = 2.0–3.0 V
ver movement to Control unit cab system, group 8.4.8.1 BOOM, menu 1
(D790-1). Boom out: US815/P2 = 3.0–4.5 V
0.5 V is the fastest retraction speed

and 4.5 V is the fastest extension
speed. Lower voltages than 0.5 V
and higher voltages than 4.5 V are
used to detect malfunctions in ca-
bling and controls.
2 Control unit cab (D790-1) sends Controlled by control and monitor- Tab 11 Common electric, group 11.5.3.1
request for Boom out or Boom in ing system, error shown with error Control unit cab
with speed information on CAN- code.
bus.
3 Control unit frame front (D797-F) I = 380-650 mA Control valve lift, lower and extension,
activates Servo valve boom out description page 36
(Y6006) or Servo valve boom in D3: Diagnostic menu, see tab 8 Control
(Y6007). system, group 8.4.8.6 BOOM, menu 6,
At retraction of the boom Control 8.4.8.7 BOOM, menu 7 and 8.4.8.2
unit frame rear (D797-R) activates BOOM, menu 2
Solenoid valve pump unloading
(Y6062).
4 Control unit cab (D790-1) sends Controlled by control and monitor- Tab 11 Common electric, group 11.5.3.1
request for increased engine rpm ing system, error shown with error Control unit cab
on CAN-bus. code.
5 Control unit engine (D794) in- Controlled by control and monitor- Tab 11 Common electric, group
creases engine rpm. ing system, error shown with error 11.5.3.10 Control unit engine
code.
6 Servo valve boom out (Y6006) or - Control valve lift, lower and extension,
Servo valve boom in (Y6007) description page 36
pressurizes the control valve's ex- D6: Diagnostic menu, see tab 8 Control
tension spool with servo pressure. system, group 8.4.8.6 BOOM, menu 6
and 8.4.8.7 BOOM, menu 7
7 The control valve's extension - Control valve lift, lower and extension,
spool changes position and pres- description page 36
surizes valve block extension cyl-
inder and sends load signal to the
hydraulic oil pumps.
8 At boom retraction, valve block - Valve block pump unloading, description

pump unloading drains the load page 40
signal to two of the hydraulic oil
pumps to tank so that only two
pumps generate pressure.

34 7 Load handling – 7.3 Protruding

9 The shuttle valve sends the - Tab 10 Common hydraulics, group
strongest load signal if several 10.5.3 Shuttle valve
functions are activated simultane-
ously.
10 The hydraulic oil pumps pump oil See pressure plate on left frame Tab 10 Common hydraulics, group
from the hydraulic oil tank. beam. 10.4.2 Axial piston pump with variable
displacement
11 The pressure reducer reduces the See pressure plate on left frame Pressure reducer, description page 15
pressure from the hydraulic oil beam.
pumps to servo pressure.
12 Servo pressure is stored in the ac- See pressure plate on left frame Accumulator servo circuit, description
cumulator. The non-return valve beam. page 17
in the pressure reducer makes it
possible to store the pressure
when the engine is shut off.
13 The servo filter filters the oil be- - Servo filter, description page 15
fore the control valve.
14 At boom in Control unit frame rear U = 24 V Valve block extension cylinder, descrip-
(D797-R) activates Servo valve, tion page 37
blocking extension (Y6050). D14: Diagnostic menu, see tab 8 Control
system, group 8.4.8.2 BOOM, menu 2
15 At boom in Servo valve, blocking - Valve block extension cylinder, descrip-

extension (Y6050) acts on the tion page 37
blocking spool in valve block ex-
tension cylinder.
16 At boom out the blocking spool in - Valve block extension cylinder, descrip-
valve block extension cylinder is tion page 37
opened by hydraulic pressure
from the control valve.
At boom in the blocking valve
opens and releases the pressure
from the extension cylinder.
17 Extension cylinder extends or re- - Extension cylinder, description page 37

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

Sensor hydraulic pressure lift cyl- description page 28
UB768-L1/2 = 0 V
inder piston side left (B768-L1) D18: Diagnostic menu, see tab 8 Control
UB768-L1/3 = 0.5–4.5 V
sends voltage signal proportional system, group 8.4.10.3 OP, menu 3
to cylinder pressure in lift cylin-
ders to Control unit frame front
(D797-F).
19 Control unit frame front (D797-F) Controlled by control and monitor- Tab 11 Common electric, group 11.5.3.2
sends information about pressure ing system, error shown with error Control unit frame front
in lift cylinders. code.

7 Load handling – 7.3.1 Hydraulic oil pump 35

20 Control unit frame rear (D797-R) U = 24 V Valve block extension cylinder, descrip-
activates Servo valve, regeneration page 37
tion (Y6046), if the pressure is suf- D20: Diagnostic menu, see tab 8 Control
ficiently low for regeneration. system, group 8.4.8.3 BOOM, menu 3
21 Servo valve, regeneration - Valve block extension cylinder, descrip-

(Y6046) pressurizes the regener- tion page 37
ation valve.
22 The regeneration valve changes - Valve block extension cylinder, descrip-

position and leads oil from the lift tion page 37
cylinder's rod side to the piston
side.
23 Extension speed increases. - Valve block extension cylinder, descrip-

tion page 37
24 Damping - Tab 8 Control system, group 8.2.1.6

When extension is approx. 0.4 m Sensor boom length
from end-position, then damping Mechanical overload system
is activated. D24: Diagnostic menu, see tab 8 Control
Mechanical overload system system, group 8.4.10.1 OP, menu 1
Sensor boom length (B769-3 or
B769-4) sends voltage signal to
Control unit frame rear (D797-R) Mechanical overload system with ana-
which sends damping on the logue position sensor, or Electronic over-
CAN-bus. load system:
D24: Diagnostic menu, seetab 8 Control
system, group 8.4.10.4 OP, menu 4 and
Mechanical overload system with 8.4.10.6 OP, menu 6
analogue position sensor, or Elec-
tronic overload system:
Sensor boom length (B777) sends
voltage signal proportional to
boom extension to Control unit
frame rear (D797-R) which sends
damping on the CAN-bus.
Hydraulic diagram basic machine

page
–

7.3.2 Servo filter

Servo filter, description
page
–
See Servo filter, description page 15.

36 7 Load handling – 7.3.3 Pressure reducer
7.3.3 Pressure reducer

Pressure reducer, description
page
–
See Pressure reducer, description page 15.
7.3.4 Accumulator servo circuit

Accumulator servo circuit, description
page
–
See Accumulator servo circuit, description page 17.
7.3.5 Manoeuvre valve lift, lower, protrude

Control valve lift, lower and extension, description
page
–
The control valve has two sections: one for the lift function and one for
9 boom extension. The sections have great similarities but are de-
scribed separately for each function.
8 For general information on the control valve, see Control valve lift low-
er and extension, description page 19.
7 1
Extension slide
6 2
The extension slide controls direction (in or out) and oil flow to valve
5 block extension cylinder.
3
Servo valve boom out
4 Servo valve boom out, controls servo pressure to the extension slide
so that it controls oil pressure for extension.
Servo valve boom out is controlled electrically with Solenoid valve
boom out (Y6006) which is activated by Control unit frame front (D797-
F).
000529
Servo valve boom in

1. Servo valve boom out (Y6006) Servo valve boom in, controls servo pressure to the extension slide so
2. Servo valve boom in (Y6007) that it controls oil pressure for boom retraction.
3. Servo valve lower (Y6004) Servo valve boom in is controlled electrically with Solenoid valve boom
4. Servo valve lift (Y6005) in (Y6007) which is activated by Control unit frame front (D797-F).
5. Connection, rod side, right lift cylinder (B2)
6. Connection, piston side, right lift cylinder (A1) The signal can be checked from the diagnostic menu, see section 8
7. Connection, feed from hydraulic oil pumps (P) Control and monitoring system, group 8.4.8.6 BOOM, menu 6.
8. Connection, rod side, extension cylinder (B1)
Shock valve, extension
9. Connection, piston side, extension cylinder (A1)
Two shock valves protect the hydraulic system against surges which
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder
piston side and tank if the pressure becomes too high.
7.3.6 Shuttle valve

page
–

7 Load handling – 7.3.7 Valve block protrude cylinder 37
7.3.7 Valve block protrude cylinder

Valve block extension cylinder, description
page
–
Valve block extension cylinder directs pressure to the extension cylin-

1
der. The valve block is located at the trailing edge of the extension cyl-
7 inder in the lift boom and contains a blocking valve, regeneration
2 valve, and non-return valve.
6
3 Blocking valve
5 The blocking valve prevents unwanted lowering. The valve holds the
4 load by keeping the connection to the extension cylinder's piston side
closed. The pressure passes through a restriction providing a blocking
pressure and holds the valve slide closed.
Solenoid valve blocking (Y6050) acts on the blocking valve. Solenoid
valve, blocking extension (Y6050) which is activated by Control unit
frame rear (D797-R).
Regeneration valve
000474
The regeneration valve directs oil from the rod side back to the piston
side. This makes it possible to re-use the oil for extension. For more
1. Connection, rod side (C-) information on regeneration, see Extension, function description page
2. Draining (D) 32. The regeneration valve is controlled by servo valve regeneration.
3. Servo valve regeneration (Y6046)
Solenoid valve, extension (Y6046) pressurises the regeneration valve.
4. Connection, control valve (VB)
Solenoid valve, extension (Y6046) is activated by Control unit frame
5. Connection, control valve (VA)
rear (D797-R).
6. Connection, control valve (VA)
7. Servo valve blocking (Y6050) The signal can be checked from the diagnostic menu, see section 8
7.3.8 Extension cylinder

Extension cylinder, description
page
–
The extension cylinder forces out and pulls in the inner boom. The ex-
tension cylinder is located in the lift boom. The rear section is secured
in the outer boom, the front section is secured in the inner boom. On
the extension cylinder is a valve block which controls pressurising of
the cylinder and regeneration for boom out.
The extension cylinder piston rod end is designed as a lug with a
flange which is secured on the piston rod with hexagonal bolts.

38 7 Load handling – 7.3.8 Extension cylinder
Extension cylinder, changing

page
–
NOTE
Safety.
Removing
2 Run out the boom until the inspection holes in the side of the in-
ner boom can be accessed.
4 Remove the lock rings and press out the pin for the front cylinder
mounting in the inner boom.
5 Machine with analogue sensor boom length.

Remove sensor boom length from the boom, see tab 8 Control
system, group 8.2.1.6 Sensor boom length.
6 Mark up and disconnect the hydraulic hoses from the extension
cylinder.
NOTE
Plug all hydraulic connections immediately.
7 Mark up and disconnect the cabling from the valve block on the
extension cylinder.
8 Remove the valve block from the extension cylinder.
NOTE
Plug all hydraulic connections immediately.
9 Remove the lock rings and press out the outer pins for the rear
cylinder mountings in the outer boom.
10 Connect lifting equipment to the rear extension cylinder mount-
ing.
11 Carefully pull out the extension cylinder. When the cylinder has
come out a short distance, connect a second lifting equipment
which is moved forward on the lift cylinder during the whole dis-
mantling to stabilize the lift.
12 Place the cylinder on wooden blocks.
Outer pins extension cylinder
13 Transfer parts to the new extension cylinder.
Installing
14 Clean and grease all bearing surfaces.

7 Load handling – 7.3.8 Extension cylinder 39
15 Measure how far the old extension cylinder is extended and pull
out the new cylinder to the same length.
NOTE
If this is not done, the front cylinder mounting will not reach
all the way.
16 Lift the extension cylinder into place.
C AUTION
Use double lifting equipment to balance the lift. The
front one shall be routed behind the support at the
leading edge of the cylinder so that it can be pushed
into the boom.
17 Install the pin at the front cylinder mounting in the inner boom.
NOTE
Grease the pin before installing.
18 Install the locks on the pin.
19 Install the pins at the rear cylinder mountings.
NOTE
Grease the pin before installing.
20 Install the locks on the pins.
21 Install the valve block on the extension cylinder.
NOTE
22 Connect the hydraulic hoses and cabling to the extension cylin-
der.
23 Machine with analogue sensor boom length.

Install sensor boom length, see tab 8 Control system, group
8.2.1.6 Sensor boom length.
24 Start the engine and check for leaks.
25 Check the oil level in the hydraulic oil tank, see tab 10 Common
hydraulics, group 10.6.8 Hydraulic oil.
26 Calibrate sensor boom length, see tab 8 Control system, group
8.5.2.1 Calibrate SCALE steps 9 - 12.

40 7 Load handling – 7.3.9 Valve block pump unloading

page
–
7.3.9 Valve block pump unloading

Valve block pump unloading, description
page
–
For boom in, only a small oil flow is required. Solenoid valve pump un-
1 2 3 4
loading (Y6062) drains the control signal to hydraulic oil pump 2, to the
tank. This results in only one pump unit building up pressure, which re-
duces the use of engine power and thus fuel consumption. If other
5 functions are activated at the same time then the pressure signal will
pass through the shuttle valve, see tab 10 Common hydraulics, group
6 10.5.3 Shuttle valve. The load signal travels to the pumps required.
10
The valve block is located standing on the bracket for the oil filling
point between the engine and transmission.
7
9 Solenoid valve pump unloading (Y6062) is supplied with voltage by
8 Control unit frame rear (D797-R) on activation.
003623
1. Solenoid valve engagement hydraulic pressure

(Y6003)
2. Pressure signal to hydraulic oil pump 2
3. Valve block top lift hydraulics
4. Tank drain
5. Pressure signal in, from shuttle valve
6. Valve block pump unloading
8. Solenoid valve pump unloading (Y6062)
9. Tank drain
10. Pressure signal in, from shuttle valve 1

7 Load handling – 7.3.10 Lift boom 41
7.3.10 Lift boom

Lift boom, general
page
–
See Lift boom, description page 30.
Slide plates lift boom, changing

page
–
NOTE
When adjusting side-mounted slide plates it is important to check
the clearance for the whole boom's stroke, and that the inner
boom is centred in the outer boom.
Front slide plates
1 Place the boom in its lowest position with the inner boom run out
approx. 50 cm.
2 Remove the cover plate for the side-mounted slide plates and re-
move the spacer plates and slide plate.
4 Check the clearance between the boom and slide plate, clear-
ance should be 1 mm. Adjust with spacer plates if needed.
NOTE
1. Side-mounted slide plates The inner boom shall be centred in the outer boom.
2. Lower slide plates 5 Remove the lock bolts and the slide plates' consoles, and pull out
the upper slide plates and spacer plates.
6 Relieve the lower slide plates, lift the inner boom at the leading
edge and use wooden spacers.
WARN IN G
Risk of crushing!
Secure the inner boom in relation to the outer boom
with wooden blocks.
7 Remove the lock bolts, slide plates' consoles and pull out the low-
er slide plates.
8 Transfer the nuts for the lock bolts for the lower slide plates to the
new slide plates.
9 Install the new lower slide plates, lock bolts, and consoles.
10 Remove the wooden blocks and let down the inner boom so that
it rests on the lower slide plates.
11 Transfer the nuts for the lock bolts for the upper slide plates to the
new slide plates.
12 Install the new slide plates, spacer plates, lock bolts, and con-
soles.

42 7 Load handling – 7.3.10 Lift boom
13 Check the clearance between the boom and stop at the leading
edge/top edge of the boom, clearance may be max. 2 mm. Ad-
just the slide plates with spacer plates if needed.
Checking attachment deformation
14 Park the machine on level ground.
15 Lower the boom completely and centre the attachment.
16
Measure the distance between extension beam and the ground
on the right and left side of the attachment.
The difference between the measurements for right (A) and left
(B) side may not be more than 50 mm at the 20'-position or 100
mm for the 40'-position.
A B Check both measurements with the boom completely retracted
008217
and completely extended.

Measuring points deformation attachment 17 If needed, adjust the lower slide plates so that the attachment is
straight.
Rear slide plates
18 Start the engine and run in the boom completely (fully retracted)
19 Remove the cover plate for the side-mounted slide plates and re-
move the spacer plates and slide plate.
21 Check the clearance between the boom and slide plate, clear-
ance should be 1 mm. Adjust with spacer plates if needed.
22 Relieve the lower slide plates, use wooden spacers.
WARN IN G
1. Upper slide plates
2. Side-mounted slide plates
3. Lower slide plates Risk of crushing!

with wooden blocks.
23 Remove cover plates, spacer plates, and the lower slide plates.
24 Install new slide plates, spacer plates, and cover plate.
25 Relieve the upper slide plates, use wooden spacers.
WARN IN G
Risk of crushing!

with wooden blocks.

7 Load handling – 7.3.11 Sensor boom length 43
26 Remove the lock bolts, the slide plates' consoles, and pull out the
upper slide plates and spacer plates.
27 Transfer the nuts for the lock bolts for the upper slide plates to the
new slide plates.
28 Install the new slide plates, spacer plates, lock bolts, and con-
soles.
29 Check the clearance between outer and inner boom, clearance
may be max. 2 mm. Adjust slide plates with spacer plates if
needed.
Lubrication
004874
Glide surfaces boom
30 Run out the inner boom completely and lubricate the glide surfac-
es inside the outer boom and on the inner boom with white lubri-
cation paste.
31 Run the boom in and out approx. 10 times and stop with the boom
completely out.
32 Wipe off excess lubrication paste by the slide plates and on the
glide surfaces.
7.3.11 Sensor boom length

Sensor boom length, general
page
–

boom length.

page
–

44 7 Load handling – 7.4 Side-shift
7.4 Side-shift
Sideshift, function description
page
–

Control switch Disengaged Tab 11 Common electric, group 11.5.1.4 Manoeuvre switch voltage
1
D1
2
D790-1
D797-R D791-1
3 7 D7
D3 8
C6
P1 A
10
9
4
T1 B
5
C6
6
006407
1 Control lever (S815-T1.1) sends voltage Left: US815-T1.1 = 24 V Control lever, description page 7
signal to Control unit cab (D790-1). D1: Diagnostic menu, see tab 8 Control sys-
Right: US815-T1.2 = 24 V
tem, group 8.4.9.2 ATTACH, menu 2
2 Control unit cab (D790-1) sends side- Controlled by control and Tab 11 Common electric, group 11.5.3.1
shift left or right on the CAN-bus. monitoring system, error Control unit cab
3 Control unit frame rear (D797-R) acti- U = 24 V Tab 11 Common electric, group 11.5.3.3
vates Solenoid valve, engagement of hy- Control unit frame rear
draulics for top lift (Y6003). D3: Diagnostic menu, see tab 8 Control sys-
tem, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hydrau- - Valve block top lift hydraulics, description
lics for top lift (Y6003) opens and pressu- page 46
rizes valve block lift cylinder and sends D3: Diagnostic menu, see tab 8 Control sys-
load signal to hydraulic oil pump 2. tem, group 8.4.5.6 HYD, menu 6


load signal to the hydraulic oil pumps if Shuttle valve
several functions are activated simulta-
neously.
6 Hydraulic oil pump 2 pumps oil from the See pressure plate on left Tab 10 Common hydraulics, group 10.4.2
hydraulic oil tank. frame beam. Axial piston pump with variable displace-
ment
7 Control unit attachment (D791-1) acti- U = 24 V Tab 11 Common electric, group 11.5.3.5
vates Servo valve, sideshift left (Y6020) Control unit attachment
or Servo valve, sideshift right (Y6021). D7: Diagnostic menu, see tab 8 Control sys-
8 Servo valve, sideshift left (Y6020) or - Control valve attachment, description page
Servo valve, sideshift right (Y6021) pres- 47
surizes the sideshift spool in control D7: Diagnostic menu, see tab 8 Control sys-
valve attachment. tem, group 8.4.9.8 ATTACH, menu 8
9 The control valve's sideshift spool - Control valve attachment, description page
changes position and pressurizes side- 47
shift cylinders.
10 The sideshift cylinders push in the main - Sideshift cylinder, description page 52
beam sideways in relation to the side-
shift frame.
Hydraulic diagram top lift

Hydraulic diagram top lift, tilt lock and controllable tilt
Hydraulic diagram combi attachment
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic level-
ling

page
–


46 7 Load handling – 7.4.2 Valve block top lift hydraulics
7.4.2 Valve block top lift hydraulics

Valve block top lift hydraulics, description
page
–
The valve block for top lift hydraulics is an electrically controlled valve.
1 2 3 4
It leads a reduced constant pressure as the load signal to the hydraulic
oil pumps when attachment functions are activated. The valve block is
located lying down on the bracket for the oil filling point between the
5 engine and transmission.
When the solenoid valve is activated, pressure is directed from the top
10 6 lift hydraulics' supply through a shuttle valve to the hydraulic oil pumps'
control. A restriction before the valve block ensures that the pressure
7 to the hydraulic oil pumps' control does not become too high. When
9 the solenoid valve is not activated, the load signal is drained to tank
8 and the inlet from the top hydraulics' supply is closed.
The valve is controlled electrically with Solenoid valve, engagement
hydraulic pressure (Y6003) which is activated by Control unit frame
rear (D797-R).
003623
Control and monitoring system, group 8.4.5.6 HYD, menu 6.
1. Solenoid valve engagement hydraulic pressure
(Y6003)
3. Valve block top lift hydraulics
4. Tank drain
5. Pressure signal in, from shuttle valve
6. Valve block pump unloading
8. Solenoid valve pump unloading (Y6062)
9. Tank drain
10. Pressure signal in, from shuttle valve 1

7 Load handling – 7.4.3 Control valve attachment 47
7.4.3 Control valve attachment

Control valve attachment, description
page
–
1 2 3 4 5 6 7 8 9 10
11
28
27 12
26
13
25
24
001098
23 22 21 20 19 18 17 16 15 14
15. Connection to spreading motor

1. Solenoid valve, tilt out (Y6010)
16. Connection to sideshift cylinder
2. Solenoid valve tilt in (Y6011)
17. Connection to sideshift cylinder
3. Solenoid valve, rotation clockwise (Y6008)
18. Connection to rotation motor
4. Solenoid valve, rotation counter-clockwise (Y6009)
19. Connection to rotation motor
5. Solenoid valve, sideshift right (Y6021)
20. Connection to tilt cylinder
6. Solenoid valve, sideshift left (Y6020)
7. Solenoid valve, spreading out (Y6018) 21. Connection to tilt cylinder
8. Solenoid valve, spreading in (Y6019)
22. Connection to levelling cylinder
9. Solenoid valve, lock twistlocks (Y6040)
23. Connection to levelling cylinder
10. Solenoid valve, open twistlocks (Y6039)
24. Test outlet feed pressure to control valve
11. Drain to tank
25. Feed from hydraulic oil pump 2
12. Connection to lock cylinder
26. Return to tank (through tank filter)
13. Connection to lock cylinder
14. Connection to spreading motor 27. Solenoid valve levelling right (Y6035)
28. Solenoid valve levelling left (Y6036)
Sideshift is controlled by a separate section in the control valve attach-

ment.
The attachment control valve controls hydraulic functions on the at-
tachment. The control valve is located in the middle of the back of the
attachment. Electric servo valves control the flow from the valve.

48 7 Load handling – 7.4.3 Control valve attachment
The control valve is an electro-hydraulically controlled, proportional

and pressure compensated direction valve. Electrically controlled ser-
vo valves convert current to servo pressure. The servo pressure con-
trols the spring centred valve slides which control pressure and flow
for the function in question. The valve slides have a flow limit in order
that several functions can be activated simultaneously, and this way
control the main flow.
The control valve has an integral pilot pressure supply. This means
that the valve has an integral pressure reducer which converts feed
pressure to servo pressure for the different functions. The pilot pres-
sure supply is common for all functions. This reduces pressure varia-
tions due to long hoses and reduces the number of hoses to the valve.
The control valve has the following sections:
• Sideshift
• Spreading
• Rotation
• Twistlocks
• Controllable tilt
• Hydraulic levelling
Sideshift slide
The valve slide controls sideshift direction and speed.
The valve slide is controlled by servo valve sideshift right and servo
valve sideshift left.
Servo valve sideshift left

Servo valve sideshift left controls pressure to the sideshift slide so that
the sideshift slide opens and pressurises the sideshift cylinders.
Servo valve sideshift left is controlled electrically with Solenoid valve,
sideshift left (Y6020) which is activated by Control unit attachment
(D791-1). The servo valve directs servo pressure to the sideshift slide
proportional to the control current to the solenoid valve.
Servo valve sideshift right

Servo valve sideshift right controls pressure to the sideshift slide so
that the sideshift slide opens and pressurises the sideshift cylinders.
Servo valve sideshift is controlled electrically with Solenoid valve,
sideshift right (Y6021) which is activated by Control unit attachment
(D791-1). The servo valve directs servo pressure to the sideshift slide

Control valve attachment, replacement

page
–
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
NOTE
4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
Remove the attaching bolts and lift away the valve. Place the
valve on a clean, protected surface.
6 Transfer the connection adapters to the new control valve.
NOTE
NOTE
Transfer one adapter at a time so that the marking is not
mixed up.
7 Mark up the servo valves on the new control valve.
8 Fit the valve.
Lift the valve into place and fit the attaching bolts.
9 Connect the wiring to the control valve in accordance with the
marking.
10 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE
12 Check that the valve's hydraulic connections are sealed.

50 7 Load handling – 7.4.3 Control valve attachment
13 Check that the attachment is working.
C AUTION

itation.
C AUTION
Overfilling of oil.


Control valve attachment, checking hydraulic

page
–
pressure
NOTE
Read the instructions for oil before working, see tab B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at

operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
˚C 2 Machine in service position, see tab B Safety.

˚C
Operating menu hydraulic oil temperature 000475
4 Connect pressure gauge to pressure check connection PL on

control valve attachment.
5 Start the engine and let it idle. Check the pressures in the attach-
ment's different functions by letting each function go to its end-
position, then read off the pressure gauge.
The pressures should be:
Function Pressure
Sideshift 16.0 MPa
Spreading 12.0 MPa

008226
Rotation 15.0 MPa
Pressure check connection control valve attachment 15.0 MPa

Tilt control
15.5 MPa
Levelling
Twistlocks Same as feed pressure.
10.0 MPa
Overheight legs lowering
10.0 MPa
Lift legs, knee out/in
13.0 MPa
Lift legs, leg down/up
13.0 MPa
Lift legs, clamp

7 Remove the pressure gauge and fit the protective cap on the
pressure check connection.

52 7 Load handling – 7.4.4 Shuttle valve
7.4.4 Shuttle valve

page
–
7.4.5 Sideshift cylinder

Sideshift cylinder, description
page
–
The sideshift cylinders are two inter-connected hydraulic cylinders that

1 push the attachment's main beam sideways in relation to the sideshift
frame. The sideshift cylinders are located along the front and back of
10 the attachment and are used to centre the load's centre of gravity.
8 2
3
4
001500
7 6 5
1. Sideshift frame
2. Sideshift cylinder
3. Position sensor spreading
4. Sensor alignment
5. Twistlock
6. Sensor twistlocks
7. Lock cylinder twistlocks
8. Spreader boom
9. Spreader motor
10. Main beam attachment

page
–

7 Load handling – 7.4.6 Sideshift frame 53
7.4.6 Sideshift frame

Sideshift frame, description
page
–
The attachment is secured in the boom with the rotation yoke. The
1 2 3 4 5 6 sideshift frame is located under the rotation yoke. The attachment's
main beam is located in the sideshift frame. The main beam can be ex-
tended laterally in relation to the sideshift frame with two hydraulic cyl-
inders. Inside the main beam are two spreader beams which can be
extended in and out with a hydraulic motor.
The position of the attachment can be adjusted laterally by moving the
main beam in relation to the sideshift frame. The main beam runs on
slide pates in the sides and in the bottom. The sideshift cylinders se-
cure the side position.
The sideshift frame is available in two versions:
• Standard top lift. The sideshift frame allows the main beam to be
000526
levelled 5°. Sideshift 800 mm.
1. Main beam • Pile-slope top lift

2. Ring gear
The sideshift frame is located in the rotation yoke with four hydrau-
3. Rotation motor unit
lic cylinders which mean that the levelling can be controlled for ad-
4. Rotation yoke
aptation to angled containers. Sideshift 800 mm. See Sideshift
5. Control valve attachment
frame, description page 111.
6. Sideshift frame
Slide plates, sideshift frame, replacement

page
–
1 Loosen the cover plate's attaching bolt and remove the cover
plate.
2 Remove the spacer plate and slide plate.
3 Repeat steps 1 - 3 on the other slide plates.

54 7 Load handling – 7.4.6 Sideshift frame
4 Measure the distance between the edge of the cover plate and
the attachment's main beam slide surface on all slide plates.
5 Centre the boom so that the distance between the attachment's
main beam and edge is the same on all slide plates.
6 Fit new a slide plate.

7 Check the slide plate's clearance by measuring the distance be-
tween slide plate and the edge for the cover plate. Clearance be-
tween the attachment's main beam and slide plate's should be 1
mm.
8 Fit spacer plates until the distance is correct.
9 Fit the cover plate.

10 Repeat steps 7 - 10 on the other slide plates.

Lubrication
004875
Glide surfaces attachment
11 Lubricate the glide surfaces on the attachment with white lubrica-
tion paste.
12 Run the sideshift completely from right to left approx. 10 times.
glide surfaces.
Lower slide plates, sideshift frame, replacement

page
–
1 Place axle stands or similar under the attachment's spreader

booms and lower the attachment on axle stands so that the side-
shift frame's lower slide plates can be accessed.
2 Turn off the engine and the main electrical power.
D ANGER
Risk of crushing!
Fit spacers between crossmember and attachment

main boom on both crossmembers.
3 Remove the attaching bolts and remove the slide plates.

4 Fit new slide plates.
5 Remove the spacer.
7 Lift the attachment and remove the stands.
The illustration shows a detached crossmember

56 7 Load handling – 7.4.7 Main beam attachment
Lubrication
004875
Slide plates attachment
tion paste.
9 Run the sideshift completely from right to left approx. 10 times.
glide surfaces.
7.4.7 Main beam attachment

Main beam attachment, description
page
–
Main beam attachment is located in the sideshift frame. Main beam

1 2 3 4 5 6 contains equipment for spreading (spreader beams, hydraulic motor,
chains, slide plates and sensors). On the attachment's main beam are
also the control valves to the attachment's hydraulic functions.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Sideshift frame

7 Load handling – 7.4.8 Unloading valve attachment 57
7.4.8 Unloading valve attachment

Relief valve attachment, description
page
–
The attachment relief valve opens a connection between the attach-

ment'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 at the trailing edge of the lift beam in front of
the transmission.
002269

page
–

58 7 Load handling – 7.5 Positioning
7.5 Positioning
Spreading, function description
page
–

Twistlocks Unlocked or by-pass Twistlocks, description page 119

activated Tab 8 Control system, group 8.2.2 By-passing
Overload system Passive Section 8 Control and monitoring system, group 8.2.1 Overload system
1 D1
+
2
D790-1
D797-R D791-1
3 7, 13 D12
D3 D7
8, 14
C6
12
P1 A
4
11, 16
T1 B
9, 15 10
5
C6
6
006408

1 Control lever (S815-T1.x and S815-T4) Spreading: US815-T4 = 24 V Control lever, description page 7
sends voltage signal to Control unit cab D1: Diagnostic menu, see tab 8 Control
Out: US815-T1.2 = 24 V
(D790-1). system, group 8.4.9.2 ATTACH, menu 2
In: US815-T1.1 = 24V
2 Control unit cab (D790-1) sends signal Controlled by control and Tab 11 Common electric, group 11.5.3.1
on CAN-bus. monitoring system, error Control unit cab
vates Solenoid valve, engagement of Control unit frame rear
hydraulics for top lift (Y6003). D3: Diagnostic menu, see tab 8 Control
system, group 8.4.5.6 HYD, menu 6

7 Load handling – 7.5 Positioning 59

4 Solenoid valve, engagement of hy- - Valve block top lift hydraulics, description
draulics for top lift (Y6003) opens and page 46
sends load signal to hydraulic oil D3: Diagnostic menu, see tab 8 Control
pumps. system, group 8.4.5.6 HYD, menu 6
neously.
ment
7 Control unit attachment (D791-1) acti- I = 350–600 mA Tab 11 Common electric, group 11.5.3.5
vates Servo valve spreading out Control unit attachment
(Y6018) or Servo valve spreading in D7: Diagnostic menu, see tab 8 Control
(Y6019). system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
8 Servo valve spreading out (Y6018) or - Control valve attachment, description page
Servo valve spreading in (Y6019) pres- 47
surizes the spreader slide in the attach- D7: Diagnostic menu, see tab 8 Control
ment's control valve. system, group 8.4.9.13 ATTACH, menu 13
9 The control valve's spreader spool - Control valve attachment, description page
changes position and directs pressure 47
to the spreader motor.
10 The motor valve block directs the pres- - Valve block positioning motor, description
sure to the motor and prevents the mo- page 65
tor from pumping (rotates faster than
supplied pressure).
11 The motor drives the chains that pull - Positioning motor, description page 65
the spreader beams out or in.
12 Sensor, end-position 20’-40’ (B769) Sensor directly opposite in- Position sensor positioning, description
sends voltage signal to Control unit at- dicator plate: U 24 V page 78
tachment (D791-1). D12: Diagnostic menu, see tab 8 Control
system, group 8.4.9.5 ATTACH, menu 5
13 Control unit attachment (D791-1) re- - Tab 11 Common electric, group 11.5.3.5
duces control current to Servo valve Control unit attachment
spreading out (Y6018)or Servo valve D7: Diagnostic menu, see tab 8 Control
spreading in (Y6019). system, group 8.4.9.13 ATTACH, menu 13
14 Servo valve spreading out (Y6018) or - Control valve attachment, description page
Servo valve spreading in (Y6019) re- 64
duces the pressure to the spreader D7: Diagnostic menu, see tab 8 Control
slide in the attachment's control valve. system, group 8.4.9.13 ATTACH, menu 13


15 The control valve's spreader spool - Control valve attachment, description page
changes position and reduces pres- 64
sure to the spreader motor.
16 Spreader motor speed decreases. - Positioning motor, description page 65

ling
Spreading 30’ stop, function description

page
–

Twistlocks Unlocked or by-pass ac- Twistlocks, description page 119

tivated Tab 8 Control system, group 8.2.2 By-passing
2
1
35
D2
30-
D1 3
D790-1
D791-1 6, 8 D5 D7
D8
5 7
006409

1 Switch stop at 30’-35’ (S1004) sends Switch in on position: Switch stop at 30’ or 35’, description page
voltage signal to Control unit cab (D790- Conn. 1: U = 0 V 10
1). D1: Diagnostic menu, see tab 8 Control
Conn 5: U = 24 V
Switch in off position:
Conn 1: U = 24 V
Conn 5: U = 24 V


2 Control lever (S815-T1.2 and S815-T4) Spreading: US815-T4 = 24 V Control lever, description page 7
sends voltage signal to Control unit cab D2: Diagnostic menu, see tab 8 Control
Out: US815-T1.2 = 24 V
In: US815-T1.1 = 24V
3 Control unit cab (D790-1) sends spread- Controlled by control and Tab 11 Common electric, group 11.5.3.1
ing 30’ on CAN-bus. monitoring system, error Control unit cab
4 Spreading is activated in the same way - Spreading, function description page 58

as the normal spreading steps 3–11.
5 When spreading nears 30’-position Sen- Sensor directly opposite in- Position sensor positioning, description
sor, end-position 30’ (B777-3) sends dicator plate: U = 24 V page 78
voltage signal to Control unit attachment D5: Diagnostic menu, see tab 8 Control
6 Control unit attachment (D791-1) damp- - Spreading, function description page 58

ens the speed in the same way as the
normal spreading steps 13–16.
7 When spreading is in 30’ position, Sen- Sensor directly opposite in- Position sensor positioning, description
sor end-position 20’-40’ (Y769) sends dicator plate: U = 24 V page 78
voltage signal. D7: Diagnostic menu, see tab 8 Control
8 Spreading is stopped by Control unit at- U=0V Control valve attachment, description
tachment (D791-1) cutting off the cur- page 64
rent to servo valve spreading out D8: Diagnostic menu, see tab 8 Control
(Y6018) or servo valve spreading in system, group 8.4.9.13 ATTACH, menu
(Y6019). 13 and 8.4.9.14 ATTACH, menu 14

ling

Automatic spreading 20-40 foot, function

page
–
description

Control switch Not activated Tab 11 Common electric, group 11.5.1.4 Manoeuvre switch voltage
Twistlocks Unlocked or by-pass activat- Twistlocks, function description page 112

ed
Overload system Passive Tab 8 Control system, group 8.2.1.1 Mechanical overloading system
Doors Closed Tab 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Tab 4 Brakes, group 4.5 Parking brake system
2 D2
1
+
3 9
D1 D790-1 D795
D791-1
4, 5, 8, 11 D10 D7
D5
D4 10 7
6
006884

1. Control lever (S815-T1.2 and Spreading: US815/T4 = 24 V Control lever, description page 7
S815-T4) sends voltage signal D1: Diagnostic menu, see tab 8 Control system,
Out: US815/T1.2 = 24 V
to Control unit cab (D790-1). group 8.4.9.2 ATTACH, menu 2
In: US815/T1.1 = 24V
2. Switch automatic spreading 20’- Switch in position on: Switch automatic spreading, description page 9
40’ (S199-2) sends voltage sig- US199-2/2 = 0 V D2: Diagnostic menu, seetab 8 Control system,
nal to Control unit cab (D790-1). group 8.4.9.4 ATTACH, menu 4
US199-2/5 = 24 V
Switch in position off:

US199-2/2 = 24 V
US199-2/5 = 24 V
3. Control unit cab (D790-1) sends Controlled by control and Tab 11 Common electric, group 11.5.3.1 Control
"automatic spreading out" or monitoring system, error unit cab
"automatic spreading in" on the shown with error code.
CAN-bus.


4. Control unit attachment (D791- - Spreading, function description page 58
1) activates spreading in the D4: Diagnostic menu, see tab 8 Control system,
same way as the normal spread- group 8.4.9.13 ATTACH, menu 13 and 8.4.9.14
ing steps 2 - 11. ATTACH, menu 14
5. Control unit attachment (D791- Buzzer active: U = 24 V Buzzer automatic spreading 20'-40', description
1) activates Buzzer automatic page 79
spreading (H9003). D5: Diagnostic menu, see tab 8 Control system,
group 8.4.9.15 ATTACH, menu 15
6. Buzzer automatic spreading Buzzer active: U = 24 V Buzzer automatic spreading 20'-40', description
(H9003) generates acoustic page 79
warning signal. D5: Diagnostic menu, see tab 8 Control system,
group 8.4.9.15 ATTACH, menu 15
7. When spreading nears the 30'- Sensor right in front of indi- Position sensor positioning, description page 78
position, Sensor, end-position cator plate: U = 24 V D7: Diagnostic menu, see tab 8 Control system,
30’ (B777-3) sends voltage sig- group 8.4.9.5 ATTACH, menu 5
nal to Control unit attachment
(D791-1).
8. Control unit attachment (D791- - Spreading, function description page 58

1) dampens spreading in the
same way as the normal spread-
ing position 13-16.
9 When automatic spreading is - Tab 11 Common electric, group 11.5.3.12 Control

active, Control unit KID (D795) unit KID
activates event menu Automatic
spreading.
10. When spreading is in the 20'-po- Sensor right in front of indi- Position sensor positioning, description page 78
sition, 30'-position, or 40'-posi- cator plate: U = 24 V D10: Diagnostic menu, see tab 8 Control system,
tion sensor end-position 20’-40’ group 8.4.9.5 ATTACH, menu 5
(B769) sends voltage signal to
Control unit attachment (D791-
1).
11. Control unit attachment (D791- I = 0 mA Control valve attachment, description page 64
1) cuts off control current to Ser- D4: Diagnostic menu, see tab 8 Control system,
vo valve spreading out group 8.4.9.13 ATTACH, menu 13 and 8.4.9.14
(Y6018)or Servo valve spread- ATTACH, menu 14
ing in (Y6019).

ling


page
–


page
–
See Valve block top lift hydraulics, description page 46.

page
–
The positioning is controlled by a separate section in the attachment's

control valve. For a more detailed general description of the valve and
component location, see Control valve attachment, description page
47.
Positioning slide
The valve slide controls positioning direction and speed. The valve
slide is controlled by servo valve positioning out and servo valve posi-
tioning in.
Servo valve positioning out

Servo valve positioning out controls pressure to the positioning slide
so that it opens and pressurises the positioning motor.
The servo valve is controlled electrically with Solenoid valve, position-
ing out (Y6018) which is activated by Control unit attachment (D791-
1). The servo valve directs servo pressure to the positioning slide pro-
portional to the control current to the solenoid valve.
Servo valve positioning in

Servo valve positioning in controls pressure to the positioning slide so
that it opens and pressurises the positioning motor.
The servo valve is controlled electrically with Solenoid valve position-
ing in (Y6019) which is activated by Control unit, attachment (D791-1).
The servo valve directs servo pressure to the positioning slide propor-
tional to the control current to the solenoid valve.

page
–
See Control valve attachment, replacement page 49.
7.5.4 Shuttle valve

page
–

7 Load handling – 7.5.5 Valve block positioning motor 65
7.5.5 Valve block positioning motor

Valve block positioning motor, description
page
–
Valve block positioning motor controls the direction of the oil to the po-
sitioning motor. The valve block is located on the positioning motor fur-
thest out to the left on the front of the attachment's main beam.
The valve block maintains balance between feed and positioning
speed. Balance means that the valve block prevents the motor from
pumping oil i.e. rotating faster than the feed of oil permits. Valve block
positioning contains over-centre valves which block the outlet if the
pressure on the outlet side is higher than the pressure on the inlet side.
I II
001004
Hydraulic diagram valve block positioning motor
7.5.6 Positioning motor

Positioning motor, description
page
–
The positioning motor pulls the positioning beams in and out in the at-
1 tachment's main beam with two chains. The positioning motor is locat-
ed furthest out to the left on the front of the attachment's main beam.
10
The hydraulic motor is built together with a planetary gear which re-
duces speed and reinforces the power of the motor. On the motor's hy-
9
draulic connections is a valve block with two over-centre valves which
prevent the motor form being turned faster than the hydraulic pressure
8 2 supplied.
3
4
001500
7 6 5
1. Sideshift frame
3. Position sensor positioning
4. Sensor alignment
5. Twistlock
8. Positioning beam
9. Positioning motor

66 7 Load handling – 7.5.6 Positioning motor
Spreader motor, replacement

page
–
NOTE
Safety.
2 Remove the cover plate on the left-hand side of the attachment's
main beam.
3 Start the engine and run out the spreading until the chain tension-
ers become visible in the inspection holes.
4 Turn off the engine and turn the start key to position I.
6 Turn the start key to position 0 and turn off the main electric pow-
er.
7 Measure and note down the chain tensioner's position to regain

the correct tension on the chain when installing.
8 Detach the chain tensioner on the motor side and release the
chain from the tensioner.
9 Remove the protective plate over the spreader motor.

7 Load handling – 7.5.6 Positioning motor 67
10 Mark up and disconnect the hydraulic hoses from the valve block
for the spreader motor.
11 Remove the spreader motor unit.
12 Transfer the valve block to the new motor unit.
NOTE
13 Clean the contact surfaces between the planetary gear and the
attachment's main beam.
14 Install the motor unit. Tighten the bolts crosswise in sequences
with increasing torque to 117 Nm.
15 Connect the hydraulic hoses to the valve block on the motor.

68 7 Load handling – 7.5.7 Positioning chains
16 Connect the spreader chain to the chain tensioner. Check that

the chain runs straight in the chain wheel on the hydraulic motor.
17 Tension the spreader chain to the same degree as before.
19 Check that the hydraulic connections seal tightly.
20 Check that spreading works.
21 Fit the protective plate over the motor.
22 Brush on Lubricating grease on the spreader chain.
23 Fit the cover plates to the attachment's main beam.
C AUTION
Overfilling of oil.

7.5.7 Positioning chains

Spreader chains, description
page
–
The spreader chains pull the extension beams in and out from the at-
tachment's main beam. The force from the spreader motor is transmit-
ted to the extension beams via two chains. The chains run inside the
attachment between the extension beams.
The chains are attached crosswise with one end attached to the bot-
M tom of one of the extension beams and the other along the side of the
other extension beam.
Openings in the sides of the extension beams and the attachment's
main beam make it possible to access the chains for maintenance.
000472
Principle diagram spreader chains

7 Load handling – 7.5.7 Positioning chains 69
Positioning chains, checking

page
–
1 Before adjustment, the clearance between the slide plates and

extension beams must be checked otherwise the chain's mount-
ings will be damaged, see tab 7 Load handling, group 7.5.8 Posi-
tioning beam.
2 Start the engine and run in the positioning to the 20-foot position,
and turn off the engine.
3 Check the C-C measurement between the twistlocks.
C-C 20-foot: 5853±3 mm
Check that both positioning beams run against the 20-foot stops
and that the distance between positioning beam and the position-
ing motor's mounting is at least 3 mm.
4 If needed, adjust the distance by moving washers between the
right and left 20-foot stop. The quantity of washers may not be
changed.
NOTE
Note the distance that the stop is adjusted.
Run out the positioning slightly so that it is possible to move the
washers.
5 Remove the cover plates on the attachment's main beam.

6 If the 20-foot stops have been adjusted, the positioning chains

should be adjusted equally (as much).
NOTE
Check the chain tensioner's vertical position so that the
chain runs straight toward the chain wheel.
7 Start the engine and run out the positioning to the 40-foot posi-
tion, and turn off the engine.
8 Check the C-C measurement between the twistlocks.
C-C 40-foot: 11985±3 mm
005105
9 If needed, adjust the 40-foot stops.

10 Start the engine and run in the positioning to the 40-foot position.
11 Wait 2 minutes and then check the tension of the chains.
Measure how much the chain can be pushed in at the hole clos-
est to the centre of the attachment. When the chain is pressed in
with a force of 250 N it should move 20–40 mm from resting po-
sition.
12 If needed, adjust the tension of the chains.
Start the engine and run out the positioning until the chain ten-
sioner is visible in the inspection hole. Adjust the chains.
NOTE
Adjust the chain max. 2 mm at a time on the chain tensioner.
005106
13 Repeat steps 9–11 until the chain tension is correct.
14
If the machine is equipped with 30-foot or 35-foot stops: Start the
engine and run out the positioning to the 30-foot or 35-foot posi-
tion. Turn off the engine and check the C-C measurement be-
tween the twistlocks.
C-C 30-foot: 8918±3 mm
C-C 35-foot: 10488±3 mm
I M P OR TA NT
Check the distance at stop from both 20' and 40'.
15 Brush lubrication grease on the positioning chain.


Spreader chain, replacement

page
–
1 Park the machine with the attachment as far down as possible.

2 Remove the cover plates on the attachment's main beam.
3 Start the engine and run out the spreading until the chain tension-
ers become visible in the inspection holes.
4 Turn off the engine and the main electrical power.
005105
5 Detach the defective chain's chain tensioner and release the

chain from the tensioner.
NOTE
Measure and note down the chain tensioner's position to re-
gain the correct tension on the chain when installing.
005105

6 Remove the defective chain's chain wheel.
NOTE
Note down the position of the spacer ring.
If the chain wheel on the motor side shall be removed then the
spreader motor must first be removed, see Spreader motor, re-
placement page 66.
7 Pull the chain out through the hole for the chain wheel so that the
chain runs along the spreader beam.
8 Secure the chain temporarily along the cable rack to prevent the
chain from jamming.
9 Pull out the spreader beam.

Use a machine or similar to pull out the spreader beam from the
attachment's main beam. Stop when the spreader beam is near
the 40-foot stop.
NOTE
Support the spreader beam so that bending stresses are
minimized. If needed, remove the upper slide plates to re-
duce the resistance.

10 Remove the boom stop from the attachment's main beam.

11 Remove the hydraulic hoses' clamping on the attachment's main
beam.
12 Disconnect the cable rack from the attachment's main beam.

Support the cable rack so that it is not damaged.
13 Pull out the spreader beam until the chain's mounting is accessi-
ble.
14 Release the chain from the spreader beam and cable rack.
15 Connect the new chain to the spreader beam.
16 Secure the chain along the cable rack so that the chain runs
straight along the spreader beam.
17 Brush on Lubricating greaseon the chain.

18 Retract the spreader beam so that the extension stop can be fit-
ted.
19 Fit the extension stop.
20 Connect the cable rack to the attachment's main beam.
21 Fit the hydraulic hoses' clamping on the attachment's main beam.
22 Push in the spreader beam until it is pressed in as fas as the oth-
er. This is important for easier installation of the chains.
23 Release the chain from the cable rack and thread it through the
chain wheel's hole.
24 Install the chain wheel. The spacer ring should be fitted on the un-
derside of the chain wheel.
If the rotation motor was removed, install it, see Spreader motor,
replacement page 66.
NOTE
Check that the chain runs straight into the chain wheels.
25 Connect the chain to the chain tensioner.
NOTE
Use a new split pin.
005105

7 Load handling – 7.5.8 Positioning beam 75
26 Lubricate the chain wheel's bearing with Lubricating grease.

27 Tension the spreader chain to the same measurements as be-
fore. Tighten the lock nut.
28 If the slide plates were removed, fit them.
30 Check that the spreading is working correctly.
31 Turn off the engine.
32 Check the chains' tension, see Positioning chains, checking page
69.
7.5.8 Positioning beam

Positioning beam, description
page
–
The positioning beams are a part of the attachment which grips in the
1 container. Two positioning beams run in the main beam. The position-
ing beams are retracted and extended with the positioning motor and
10 the positioning chains.
There are twistlocks located in the positioning beam, see Twistlocks,
9
description page 119.
8 2
3
4
001500
7 6 5
1. Sideshift frame
3. Position sensor positioning
4. Sensor alignment
5. Twistlock
8. Positioning beam
9. Positioning motor

76 7 Load handling – 7.5.8 Positioning beam
Slide plates, extension beams, changing

page
–

2 Take the strain off the slide plate in question.
The pressure can be removed from the slide plates by raising the
outer edges of the extension beam or inserting wedges to alter
the position of the extension beam in the attachment's main
beam.
The illustration shows the inner slide plates in the at-

tachment's main beam.
3 Remove the attaching bolts for the slide plate's bracket.
4 Remove the guide plate's guide pin.
5 Pull out the slide plate with spacer plate and bracket.
The illustration shows the inner slide plates in the at-

tachment's main beam.
6 Fit the new slide plate in the correct position.
Check the clearance between the extension beam and slide
plate. The clearance must be max. 1 mm with all slide plates in-
stalled.
Use a spacer plate to adjust the clearance.
7 Fit the slide plate's bracket and guide pin.

7 Load handling – 7.5.9 Main beam attachment 77
Lubrication
004875
tion paste.
9 Run spreading completely in and out approx. 10 times and check
the spreading function.
glide surfaces.
11 Try lifting a container and check the extension beams' clearance
in the attachment's main beam.
7.5.9 Main beam attachment

page
–
See Main beam attachment, description page 56.

78 7 Load handling – 7.5.10 Position sensor positioning
7.5.10 Position sensor positioning

Position sensor positioning, description
page
–
Position sensor positioning indicates the position of the positioning

1 2 3 4 5
beams. The position sensors are used to control positioning so that
twistlocks fit on the container. The position sensors are located under
the protective plate on the top side of the attachment's main beam on
the left side.
Sensor end-position (B769) indicates end-position for 20 and 40 foot
containers. The sensor senses the end-positions of the positioning
beams with two indicator plates on the top side of the positioning
beam. The sensor is used to activate damping.
For the optional 30 foot stop an extra sensor is installed, Sensor posi-
tion (B779), and two indicator plates. The sensor is used to activate 30
foot stop.
The sensors are supplied with voltage and send a 24 V signal to Con-
trol unit attachment (D791-1) when the raised parts of the indicator
plates pass the sensor. On the positioning beam there are indicator
plates mounted so that the sensors give a signal when the positioning
unit passes the sensor. The indicator plates' and sensors' positions
are adapted so that the distance between the spreaders becomes 20’,
(30’) and 40’.
003165
1. Indicator plate 20’
2. Sensor damping 20’ and 40’, Stop 30’
3. Sensor damping 30’
4. Indicator plate 30’ or 35’
5. Indicator plate 40’
Position sensor, checking and adjustment

page
–
See Position sensor, checking and adjustment page 5.

page
–
See Relief valve attachment, description page 57.

page
–

7 Load handling – 7.5.13 Summer automatic positioning 20'-40' 79
7.5.13 Summer automatic positioning 20'-

40'
Buzzer automatic spreading 20'-40', description
page
–
Buzzer automatic spreading 20'-40' (H9003) is located on the boom

nose on machines equipped with automatic spreading 20'-40'. The
buzzer is activated during automatic spreader movement.

80 7 Load handling – 7.6 Rotation
7.6 Rotation
Rotation, function description
page
–

D1
1
2
D790-1
D797-R D791-1
3 7
D8
D4
8
C6
P1 A
11, 12
4 T1 B
9 10
C6 5
Pos Explanation Signal description Reference 006410
1 Control lever (S815-P3) sends voltage Counter-clockwise: Tab 9 Frame, body, cab and accessories,
signal proportional to lever movement to US815/P3 = 0.5–2.0 V group 9.1 Controls and instrumentation
Control unit cab (D790-1). D1: Diagnostic menu, see tab 8 Control sys-
Zero position: US815/P3
= 2.0–3.0 V tem, group 8.4.9.1 ATTACH, menu 1
Clockwise: US815/P3 =
3.0–4.5 V
0.5 V and 4.5 V, respec-
tively, is the fastest ro-
tation speed. Lower
voltages than 0.5 V and
higher voltages than 4.5
V are used to detect
malfunctions in cabling
and controls.

7 Load handling – 7.6 Rotation 81

2 Control unit cab (D790-1) sends rotation Controlled by control Tab 11 Common electric, group 11.5.3.1
clockwise or rotation counter-clockwise and monitoring system, Control unit cab
on CAN-bus. error shown with error
code.
3 Control unit cab (D790-1) sends rotation Controlled by control Tab 11 Common electric, group 11.5.3.1
clockwise to stop or rotation counter- and monitoring system, Control unit cab
clockwise to stop on CAN-bus. error shown with error
code.
draulics for top lift (Y6003). D4: Diagnostic menu, see tab 8 Control sys-
rizes valve block lift cylinder and sends D4: Diagnostic menu, see tab 8 Control sys-
load signal to hydraulic oil pumps. tem, group 8.4.5.6 HYD, menu 6
load signal to hydraulic oil pump 2 if sev- Shuttle valve
eral functions are activated simultane-
ously.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on Tab 10 Common hydraulics, group 10.4.2
hydraulic oil tank. left frame beam. Axial piston pump with variable displacement
8 Control unit attachment (D791-1) acti- I = 435–650 mA Tab 11 Common electric, group 11.5.3.5
vates Servo valve, rotation clockwise or Control unit attachment
Servo valve, rotation counter-clockwise. D8: Diagnostic menu, see tab 8 Control sys-
tem, group 8.4.9.11 ATTACH, menu 11 and
ATTACH, menu 12
9 Servo valve rotation clockwise (Y6008) or - Control valve attachment, description page
Servo valve rotation counter-clockwise 84
(Y6009) pressurizes rotation slide in con- D8: Diagnostic menu, see tab 8 Control sys-
trol valve attachment. tem, group 8.4.9.11 ATTACH, menu 11 and
ATTACH, menu 12
10 The rotation spool in control valve attach- - Control valve attachment, description page
ment changes position and directs pres- 84
sure to Valve block hydraulic motor.
11 Valve block hydraulic motor directs pres- - Valve block rotation motor, description page
sure to both motors. 85
12 Hydraulic motors' disc brakes are re- - Rotation motor unit, description page 86
leased.
13 Hydraulic motors rotate the attachment. - Rotation motor unit, description page 86


82 7 Load handling – 7.6 Rotation

ling
Rotation stop, function description

page
–
Rotation stop is used to avoid rotating the attachment into the boom in
lifted position.
Condition Reference val- Reference

ue
1 D1
2
3 7
D2 D790-1 D795
D791-1 D5
6
D6
006411

1 Switch rotation stop (S1014) sends Switch in on position: Tab 9 Frame, body, cab and accessories,
voltage signal to Control unit cab US1014/1 = 0 V group 9.1 Controls and instrumentation
(D790-1). D1: Diagnostic menu, see tab 8 Control
US1014/5 U = 24 V
system, group 8.4.9.21 ATTACH, menu
Switch in off position: 21
US1014/1 = 24 V
US1014/5 U = 24 V


2 Control lever (S815-P3) sends voltage Counter-clockwise: US815/P3 Tab 9 Frame, body, cab and accessories,
signal proportional to lever movement = 0.5–2.0 V group 9.1 Controls and instrumentation
to Control unit cab (D790-1). D2: Diagnostic menu, see tab 8 Control
Zero position: US815/P3 = 2.0–
3.0 V system, group 8.4.9.1 ATTACH, menu 1
Clockwise: US815/P3 = 3.0–

4.5 V
0.5 V is the slowest rotation
speed and 4.5 V is the fastest
rotation speed. Lower voltag-
es than 0.5 V and higher volt-
ages than 4.5 V are used to
detect malfunctions in cabling
and controls.
3 Control unit cab (D790-1) sends rota- Controlled by control and Tab 11 Common electric, group 11.5.3.1
tion clockwise to stop or rotation coun- monitoring system, error Control unit cab
ter-clockwise to stop on CAN-bus. shown with error code.
4 Rotation is activated in the same way - Rotation, function description page 80

as the normal rotation steps 3–12.
5 Sensor rotation stop (B7225) sends Sensor directly opposite indi- Sensor rotation stop, description page 93
voltage signal to Control unit attach- cator plate: U = 24 V D5: Diagnostic menu, see tab 8 Control
ment (D791-1). system, group 8.4.9.21 ATTACH, menu
21
6 Rotation is stopped by Control unit at- - Control valve attachment, description

tachment (D791-1) cutting off the cur- page 84
rent to servo valve rotation clockwise D6: Diagnostic menu, see tab 8 Control
(Y6008) or servo valve rotation coun- system, group 8.4.9.11 ATTACH, menu
ter-clockwise (Y6009). 11 and ATTACH, menu 12
7 When the rotation stop has reached, - Tab 11 Common electric, group 11.5.3.12
Control unit KID (D795) activates Control unit KID
event menu rotation stop.

ling

page
–


84 7 Load handling – 7.6.2 Valve block top lift hydraulics

page
–

page
–
Rotation is controlled by a separate section in the attachment's control

valve. For a general description of the valve and component location,
see Control valve attachment, description page 47.
Rotation slide
The valve slide controls rotation direction and speed. The valve slide
is controlled by servo valve rotation clockwise and servo valve rotation
anticlockwise.
Servo valve rotation clockwise

Servo valve rotation clockwise controls pressure to the rotation slide
so that the rotation slide opens and pressurises the rotation motors.
Servo valve rotation clockwise is controlled electrically with Solenoid
valve, rotation clockwise (Y6008) which is activated by Control unit at-
tachment (D791-1). The servo valve directs servo pressure to the ro-
tation slide proportional to the control current to the solenoid valve.
Servo valve spreading counter-clockwise

Servo valve rotation anticlockwise controls pressure to the rotation
slide so that the rotation slide opens and pressurises the rotation mo-
tors.
Servo valve rotation anticlockwise is controlled electrically with Sole-
noid valve, rotation anticlockwise (Y6009) which is activated by Con-
trol unit attachment (D791-1). The servo valve directs servo pressure
to the rotation slide proportional to the control current to the solenoid
valve.

page
–

7 Load handling – 7.6.4 Shuttle valve 85
7.6.4 Shuttle valve

page
–
7.6.5 Valve block rotation motor

Valve block rotation motor, description
page
–
Valve block rotation motor controls pressure to the rotation motors.

The valve block is located on one of the rotation motors.
The valve block provides a controlled rotation by preventing the load
from pulling away and provides faster rotation than the hydraulic mo-
tor. The valve block contains a shuttle valve and over-centre valves.
1
1
2
2
3 3
4 4
6 5
7
000530
1. Hydraulic motor, rotation

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Sideshift frame

86 7 Load handling – 7.6.6 Rotation motor unit
7.6.6 Rotation motor unit

Rotation motor unit, description
page
–
The rotation motors rotate the attachment in relation to the boom. The
motors are located along the attachment's rotation yoke. The motors
work against the ring gear between the rotation yoke and the sideshift
frame. The rotation motor unit consists of hydraulic motor, disc brake
and planetary gear which is built together to one unit.
The hydraulic motor is located on the disc brake housing. Between the
motor and the discs is a gear wheel.
The disc brake prevents accidental rotation. The disc brake is applied
with springs and is disengaged when the hydraulic pressure is built up
1 to rotate the yoke.
1
2 The planetary gear reinforces the output in the motor and disc brake.
2 The planetary gear changes the motor speed down so that the motor
3 power is greater.
3
4 4
6 5
7
000530

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Sideshift frame

7 Load handling – 7.6.6 Rotation motor unit 87
Rotation motor unit, changing

page
–
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the motor.
NOTE
4 Remove the hydraulic motor's attaching bolts.
5 Lift away the rotation motor unit. Place the motor unit so that
gears and planet gear are not damaged.
6 Clean the contact surfaces on the motor unit and rotation yoke.
7 Lift the new motor unit into place.
8 Install the motor unit. Tighten the screws crosswise in sequences
with increasing torque to 117 Nm.

88 7 Load handling – 7.6.7 Rotation yoke
9 Connect the hydraulic hoses to the motor and brake in accord-

ance with the marking.
NOTE
11 Check that the hydraulic connections seal tightly.
12 Check that the rotation is working.
C AUTION
Overfilling of oil.

7.6.7 Rotation yoke

Rotation yoke, description
page
–
The rotation yoke is a part of the attachment which connects the at-
1 2 3 4 5 6 tachment to the boom. The rotation yoke is secured on the inner boom
with two shafts which run in bearing equipped attaching lugs. In the
bottom of the rotation yoke is the ring gear with lead-through bolts.
Using the rotation motors which act on the ring gear the remaining
parts of the attachment can be rotated in relation to the lift boom.
The rotation yoke's mounting in the lift boom facilitates longitudinal
motion (so-called "tilt"). The oscillating motion is dampened by two hy-
draulic cylinders which are secured between the upper yoke and the
upper edge on the inner boom.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Sideshift frame

7 Load handling – 7.6.7 Rotation yoke 89
Rotation yoke, replacement

page
–
1 Clean the attachment and boom nose.

2 Release the attachment from the boom.
3 Remove the rotation motors from the rotation yoke.
4 Fit the lifting equipment on the rotation yoke.
5 Remove the pipes for ring gear lubrication.
The illustration shows removed rotation yoke and ring

gear.
6 Remove the rotation yoke attaching bolts.
7 Lift away the rotation yoke.
8 Clean the contact surfaces on the ring gear.
9 Remove the plastic plugs and clean the threads and holes on the
new rotation yoke, clean the contact surface against the ring
gear.
10 Transfer parts to the new rotation yoke.
• Grease cups
• Mounting pins
11 Transfer the lifting equipment to the new rotation yoke.
12 Lift the new rotation yoke into place.
NOTE
Align the position against that of the ring gear so that the lu-
brication lines can be fitted.
13 Grease the rotation yoke's mounting pins with grease, and place
them in the rotation yoke.

90 7 Load handling – 7.6.7 Rotation yoke
14 Tighten the rotation yoke's attaching bolts with torque, 331 Nm.
15 Install the pipes for the ring gear's lubrication lines.

16 Grease the ring gear.
Rotate the yoke while greasing it so that the grease is distributed
evenly.
17 Rotate the yoke so that it is straight.
18 Install the rotation motors. See Rotation yoke, description page
88.
NOTE
If necessary, rotate the rotation yoke so that the rotation mo-
tor's gear wheel fits against the ring gear.
19 Connect the attachment to the boom.
20 Start the motor and check that the rotation is working.
21 Clean the attachment.
C AUTION
Overfilling of oil.


7 Load handling – 7.6.8 Ring gear 91
7.6.8 Ring gear

Ring gear, description
page
–
The ring gear is the joint between the rotation yoke and the sideshift
frame. The ring gear consists of gear wheel, bearings and mounting
parts. The unit is bolted into the rotation yoke and sideshift frame.
1
1
2
2
3 3
4 4
6 5
7
000530

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Sideshift frame
Ring gear, changing

page
–
1 Remove the rotation yoke, see Rotation yoke, replacement page

89.
2 Remove the lubricating pipes from the ring gear.
NOTE
Note down the locations of the lubricating pipes to facilitate
fitting.
The illustration shows removed rotation yoke and ring 3 Remove the attaching bolts between the ring gear and the side-
gear. shift frame.
4 Lift away the ring gear.

92 7 Load handling – 7.6.9 Sideshift frame
5 Clean the contact surfaces on the sideshift frame and ring gear.
6 Lift the new ring gear into place.
NOTE
Rotate it so that the connections for the lubricating pipes are
in the same positions as before.
7 Lubricate the inner attaching bolts with Lubricating grease and in-
stall them. Tighten the screws crosswise in sequences with in-
creasing torque to 331 Nm.
8 Fit the rotation yoke, see Rotation yoke, replacement page 89.
9 Fit the lubricating pipes to the ring gear.
10 Lubricate the ring gear with Lubricating grease.
11 Start the motor and check the function of the rotation.
The illustration shows removed rotation yoke and ring

gear.
C AUTION
Overfilling of oil.


page
–
See Sideshift frame, description page 53.

7 Load handling – 7.6.10 Sensor rotation stop 93
7.6.10 Sensor rotation stop

Sensor rotation stop, description
page
–
Sensor rotation stop (B7225) indicates when rotation is 25° from the
middle position and is used to activate rotation stop. The sensor is lo-
cated on a bracket on the left side of the rotation yoke and senses 25°
towards the rotation yoke's mechanical stop.
The sensors are supplied with voltage and send 24 V signal to Control
unit attachment (D791-1) when the raised parts pass the sensor.

page
–

page
–

page
–

94 7 Load handling – 7.7 Tilt
7.7 Tilt
Tilt damping, function description
page
–
2
C1-
A C2+
C
B C1+
C2- 3
1
000461
1 Hydraulic oil pump 2 pumps oil. See pressure plate on left Tab 10 Common hydraulics, group 10.4.2 Axial
frame beam. piston pump with variable displacement
2 Damping block tilt distributes oil to - Damping block tilt, description page 100
the tilt cylinders.
3 The tilt cylinders dampen the at- - Tilt cylinder, description page 103
tachment's movements.

7 Load handling – 7.7 Tilt 95
Tilt lock, function description

page
–
1 D1
2 11
D790-1 D795
D797-R D791-1
3 7
D3 8 D7
C1-
A C2+
10
4
B C1+
C2-
5 9
C6
6
006412
1 Control lever (S815-T3.1) sends voltage US815-T3.1 = 24 V Tab 9 Frame, body, cab and accessories,
signal proportional to lever movement to group 9.1 Controls and instrumentation
Control unit cab (D790-1). D1: Diagnostic menu, see tab 8 Control sys-
2 Control unit cab (D790-1) sends tilt lock Controlled by control and Tab 11 Common electric, group 11.5.3.1
on CAN-bus. monitoring system, error Control unit cab
3 Control unit frame rear (D797-R) acti- U = 24 V Valve block top lift hydraulics, description
vates Solenoid valve, engagement of page 46
hydraulics for top lift (Y6003). D3: Diagnostic menu, see tab 8 Control sys-
lics for top lift (Y6003) opens and pres- page 46
surizes valve block lift cylinder and D3: Diagnostic menu, see tab 8 Control sys-
sends load signal to hydraulic oil pumps. tem, group 8.4.5.6 HYD, menu 6
neously.


ment
7 Control unit attachment (D791-1) acti- Float mode: U = 24 V Tab 11 Common electric, group 11.5.3.5
vates Servo valve, tilt lock (Y6012). Lock mode: U = 0 V Control unit attachment
D7: Diagnostic menu, see tab 8 Control sys-
8 Servo valve tilt lock (Y6012) pressurizes - Lock valve tilt, description page 102
the lock valve in the attachment's control D7: Diagnostic menu, see tab 8 Control sys-
valve. tem, group 8.4.9.15 ATTACH, menu 15
9 The lock valve changes position and - Lock valve tilt, description page 102
blocks the connections to the tilt cylin-
ders.
10 The tilt cylinders lock the attachment's - Tilt cylinder, description page 103
angle.
11 When tilt lock is activated, Control unit - Tab 11 Common electric, group 11.5.3.12
KID (D795) shows event menu tilt lock. Control unit KID
When tilt lock is activated the machine's
speed is limited to max. 5 km/h.

ling

7 Load handling – 7.7 Tilt 97
Tilt control, function description

page
–

ue
D1
1
2
D790-1
D797-F D791-1
3 7
D3
8 10 D10
C6 D8
C1-
P1 A A C2+
12
4
T1 B B C1+
C2-
C6 9 11
5
6
006885
1 Control lever (S815-P4) sends voltage Tilt out: US815/P4 = 0.5– Tab 9 Frame, body, cab and accessories,
signal proportional to lever movement 2.0 V group 9.1 Controls and instrumentation
to Control unit cab (D790-1). D1: Diagnostic menu, see tab 8 Control sys-
2.0–3.0 V tem, group 8.4.9.1 ATTACH, menu 1
Tilt in: US815/P4 = 3.0–4.5

V
2 Control unit cab (D790-1) sends tilt in or Controlled by control and Tab 11 Common electric, group 11.5.3.1
tilt out on CAN-bus. monitoring system, error Control unit cab


surizes valve block lift cylinder and D3: Diagnostic menu, see tab 8 Control sys-
sends load signal to hydraulic oil tem, group 8.4.5.6 HYD, menu 6
pumps.
neously.
ment
7 Control unit attachment option (D791-2) I = 400–650 mA Tab 11 Common electric, group 11.5.3.6
activates Servo valve, tilt out (6010) or Control unit attachment option or tab 11
Servo valve, tilt in (Y6011). Common electric, group 11.5.3.8 Control
unit attachment right legs
Machine with lift legs
Control unit attachment right leg pair tem, group 8.4.9.16 ATTACH, menu 16 and
(D791-4) activates Servo valve, tilt out ATTACH, menu 17
(6010) or Servo valve, tilt in (Y6011).
8 Servo valve, tilt out (Y6010) or Servo - Control valve attachment, description page
valve, tilt in (Y6011) pressurizes the tilt 102
slide in the attachment's control valve. D8: Diagnostic menu, see tab 8 Control sys-
tem, group 8.4.9.16 ATTACH, menu 16 and
ATTACH, menu 17
9 The control valve's tilt spool changes - Control valve attachment, description page
position and pressurizes the damping 102
block.
10 Control unit attachment (D791-1) acti- Float mode: U = 24 V Tab 11 Common electric, group 11.5.3.5
vates Servo valve, tilt lock (Y6012). Lock mode: U = 0 V Control unit attachment
D10: Diagnostic menu, see tab 8 Control
11 Servo valve tilt lock (Y6012) pressuriz- - Lock valve tilt, description page 102
es the lock valve in the attachment's D10: Diagnostic menu, see tab 8 Control
control valve. system, group 8.4.9.15 ATTACH, menu 15
12 The lock valve changes position and - Damping block tilt, description page 100
leads oil crosswise to the tilt cylinders.
13 The tilt cylinders change the attach- - Tilt cylinder, description page 103
ment's angle.

ling

Tilt damping, adjusting

page
–
NOTE
Safety.
NOTE
The tilt damping may have to be adjusted after run-in due to me-
chanical tolerances.
1 Engine at idle.
2 Lift the boom without load and check that the attachment hangs
horizontally during the whole lifting movement.
3 Adjust tilt damping as needed by adjusting the screws on the
damping block. Adjust both screws equally.
1 Clockwise: increase damping.
Counter-clockwise: reduce damping.
4 Lift a loaded container, test-run and brake, check that the con-
tainer does not swing uncontrollably. If needed, adjust the damp-
ing acc. to step 3.
5 Start the machine and check that the function is satisfactory.
005350
1. Adjusting screws

page
–


page
–

100 7 Load handling – 7.7.3 Damping block tilt
7.7.3 Damping block tilt

Damping block tilt, description
page
–
The damping block contains restrictions which create resistance to the

1
tilt cylinder's movements which in turn dampen the attachment's oscil-
lations. The damping block is located in the centre of the boom nose.
The damping block is supplied with oil via the return from the attach-
ment's control valve. The feed means that the cylinders are always
filled with oil. Tuned restrictions mean that the feed does not affect the
2 2
tilting. The constant feed means that the tilt cylinders do not need
bleeding after work on tilting.
The damping block contains two shock valves which protect the valve
against surges.
000535
1. Damping block
2. Tilt cylinder
Damping block tilt, replacement

page
–
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the valve block.
NOTE
4 Remove the valve block from the boom.

7 Load handling – 7.7.3 Damping block tilt 101
5 Transfer the connection adapters to the new valve. Transfer one

adapter at a time so that the marking is not mixed up.
NOTE
6 Fit a new valve block to the boom nose.
The illustration shows the damping block with control-

lable tilt.
7 Connect the hydraulic hoses to the damping block in accordance
with the marking.
NOTE
8 Start the machine and check seal integrity and function.
Check both tilt and attachment functions.
C AUTION
Overfilling of oil.


102 7 Load handling – 7.7.4 Lock valve tilt
7.7.4 Lock valve tilt

Lock valve tilt, description
page
–
On machines with tilt lock, there are two solenoid valves on the damp-
ing block's return lines. When the solenoid valves are activated the
connection between the cylinders is blocked and locks the tilt position.
The lock valves are located on the damping block.
Solenoid valve tilt (Y6012) is supplied with voltage by Control unit at-
tachment option (D791-2) when tilt lock is not activated.

page
–
Controllable tilt is controlled by a separate section in the attachment's

control valve. For a general description of the valve and component lo-
cation, see Control valve attachment, description page 47.
Tilt slide
The valve slide controls direction and speed of attachment tilting.
The valve slide is controlled by servo valve tilt in and servo valve tilt
out.
Servo valve tilt out

Servo valve tilt out controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
Servo valve tilt out is controlled electrically with Solenoid valve, tilt out
(Y6010) which is activated by Control unit attachment option (D791-2).
The servo valve directs servo pressure to the tilt slide proportional to
the control current to the solenoid valve.
Servo valve tilt in

Servo valve tilt in controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
Servo valve tilt in is controlled electrically with Solenoid valve, tilt in
(Y6011) which is activated by Control unit attachment option (D791-2).
The servo valve directs servo pressure to the tilt slide proportional to
the control current to the solenoid valve.

page
–

7.7.6 Shuttle valve

page
–
7.7.7 Tilt cylinder

Tilt cylinder, description
page
–
The tilt cylinders are located between the inner boom's front edge and
1
the rotation yoke's upper section. The two cylinders are positioned di-
agonally and can therefore effectively dampen or control tilt motion.
The piston rod bracket is welded to the piston rod, which is threaded
in the piston head and locked with a lock bolt. The cylinder head is
threaded in the cylinder pipe.
2 2
000535
1. Damping block
2. Tilt cylinder

page
–
7.7.8 Lift boom

Lift boom, general
page
–
See Lift boom, description page 30.
7.7.9 Rotation yoke

Rotation yoke, general
page
–
See Rotation yoke, description page 88.

page
–

page
–

104 7 Load handling – 7.8 Levelling
7.8 Levelling
Hydraulic levelling, function description
page
–

D1
1
2
+ D790-1
D791-2
D797-R
3 D791-3 7 9
D8
D9
D4
10 8
C6 14
P1 A
4 T1 B
11 12 13
5
C6
006888

1 Control lever (S815-P3) sends volt- Levelling right: US815/P3 = Tab 9 Frame, body, cab and accessories, group
age signal proportional to lever 0.5–2.0 V 9.1 Controls and instrumentation
movement, at the same time as Con- D1: Diagnostic menu, see tab 8 Control system,
trol lever (S815-T4) sends voltage to group 8.4.9.1 ATTACH, menu 1
2.0–3.0 V
Levelling left: US815/P3 =
3.0–4.5 V
US815/T4 = 24 V
2 Control unit cab (D790-1) sends lev- Controlled by control and Tab 11 Common electric, group 11.5.3.1 Con-
elling left or levelling right on CAN- monitoring system, error trol unit cab
bus. shown with error code.

7 Load handling – 7.8 Levelling 105

3 Control unit frame rear (D797-R) ac- U = 24 V Tab 11 Common electric, group 11.5.3.3 Con-
tivates Solenoid valve, engagement trol unit frame rear
of hydraulics for top lift (Y6003). D4: Diagnostic menu, see tab 8 Control system,
group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hy- - Valve block top lift hydraulics, description page
draulics for top lift (Y6003) opens 46
connection between the pumps and D4: Diagnostic menu, see tab 8 Control system,
the attachment's control valve. group 8.4.5.6 HYD, menu 6
5 The shuttle valve sends the strong- - Tab 10 Common hydraulics, group 10.5.3 Shut-
est load signal to the hydraulic oil tle valve
pumps if several functions are acti-
vated simultaneously.
6 Hydraulic oil pump 2 pumps oil from See pressure plate on left Tab 10 Common hydraulics, group 10.4.2 Axial
the hydraulic oil tank. frame beam. piston pump with variable displacement
7 Control unit attachment option U = 24 V Tab 11 Common electric, group 11.5.3.6 Con-
(D791-2) or activates Solenoid valve trol unit attachment option or tab 11 Common
levelling (Y6034). electric, group 11.5.3.7 Control unit attachment
left legs
Machine with combi attachment
D8: Diagnostic menu, see tab 8 Control system,
Control unit attachment left legs group 8.4.9.18 ATTACH, menu 18
(D791-3) activates Solenoid valve
levelling (Y6034).
8 Solenoid valve levelling opens con- - Valve block levelling cylinders, description page
nection to levelling cylinders in Valve 110
block levelling cylinders.
9 Control unit attachment option I = 400–650 mA Tab 11 Common electric, group 11.5.3.6 Con-
(D791-2) or Control unit attachment trol unit attachment option or tab 11 Common
left legs (D791-3) activates Servo electric, group 11.5.3.7 Control unit attachment
valve levelling right (Y6035) or Servo left legs
valve levelling left (Y6036). D9: Diagnostic menu, see tab 8 Control system,
group 8.4.9.19 ATTACH, menu 19 and AT-
TACH, menu 20
10 Servo valve levelling right (Y6035) or - Control valve attachment, description page 108
Servo valve levelling left (Y6036) act D9: Diagnostic menu, see tab 8 Control system,
on the levelling slide in control valve group 8.4.9.19 ATTACH, menu 19 and AT-
attachment. TACH, menu 20
11 The control valve's levelling spool - Control valve attachment, description page 108
changes position and pressurizes
the over-centre valve levelling.
12 The over-centre valve opens and - Over-centre valve leveling, description page
leads the pressure to valve block lev- 109
elling cylinders.
13 Valve block levelling cylinders leads - Valve block levelling cylinders, description page
the pressure on to levelling cylinders. 110

106 7 Load handling – 7.8 Levelling

14 The levelling cylinders lock the at- - Levelling cylinders, description page 110
tachment's angle.

ling
Levelling lock, function description

page
–

D1
1 2 10
D790-1 D795
D791-2
D797-F
3 D791-3 7 D8
D4
8
C6
P1 A
9
4 T1 B
5
C6
6
006889

1 Control lever (S815-T3.1) sends voltage US815-T3.1 = 24 V Tab 9 Frame, body, cab and accessories,
signal to Control unit cab (D790-1). group 9.1 Controls and instrumentation

7 Load handling – 7.8 Levelling 107

2 Control unit cab (D790-1) sends level- Controlled by control and Tab 11 Common electric, group 11.5.3.1
ling lock on CAN-bus. monitoring system, error Control unit cab
3 Control unit frame rear (D797-R) acti- U = 24 V Valve block top lift hydraulics, description
vates Solenoid valve, engagement of page 46
lics for top lift (Y6003) opens connection page 46
between the pumps and the attach- D4: Diagnostic menu, see tab 8 Control sys-
ment's control valve. tem, group 8.4.5.6 HYD, menu 6
neously.
6 The hydraulic oil pumps pump oil from See pressure plate on left Tab 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. frame beam. Axial piston pump with variable displace-
ment
7 Control unit attachment option (D791-2) U=0V Valve block levelling cylinders, description
cuts off activation Solenoid valve level- page 110
ling (Y6034). D8: Diagnostic menu, see tab 8 Control sys-
Machine with combi attachment.
Control unit attachment left legs (D791-
3) cuts off activation Solenoid valve lev-
elling (Y6034).
8 Solenoid valve levelling (Y6034) blocks - Valve block levelling cylinders, description
connections to levelling cylinders in page 110
valve block levelling cylinders. D8: Diagnostic menu, see tab 8 Control sys-
9 The levelling cylinders change the at- - Levelling cylinders, description page 110
tachment's angle.
10 When tilt lock is activated, event menu - Tab 11 Common electric, group 11.5.3.12
shows tilt lock. Control unit KID
When levelling lock is activated the ma-
chine's speed is limited to max. 5 km/h.

ling


page
–


page
–

page
–
Hydraulic levelling is controlled by a separate section in the control

valve attachment. For a general description of the valve and compo-
nent location, see Control valve attachment, description page 47.
Levelling slide
The valve slide controls direction and speed of attachment levelling.
The valve slide is controlled by servo valve levelling right (Y6035) and
servo valve levelling left (Y6034).
Servo valve levelling right

Servo levelling right controls pressure to the levelling slide so that it
opens and pressurises the levelling cylinders.
Servo valve levelling right is controlled electrically with Solenoid valve,
levelling right (Y6035) which is activated by Control unit attachment
option (D791-2). The servo valve directs servo pressure to the tilt slide
Servo valve levelling left

Servo levelling left controls pressure to the levelling slide so that it
opens and pressurises the levelling cylinders.
Servo valve levelling left is controlled electrically with Solenoid valve
levelling left (Y6036) which is activated by Control unit, attachment
(D791-2). The servo valve directs servo pressure to the tilt slide pro-
portional to the control current to the solenoid valve.
Passive levelling
The servo valves open a connection to the tank, in addition, hydraulic
oil can flow between right and left-hand side levelling cylinders, from
piston sides to rod sides, in accordance with inclination.

Active levelling
Levelling is monitored by the sequence valves in valve block levelling
cylinder, which close when the feed pressure is high enough to set all
cylinders in bottom position. Following which, hydraulic oil is fed to the
rod sides on one side's cylinders and the side lifts. When levelling, the
other side will thus always be in its lowest position. This always gives
maximal levelling travel.

page
–
7.8.4 Shuttle valve

page
–
7.8.5 Over-centre valve levelling

Over-centre valve leveling, description
page
–
The over-centre valve makes sure that the leveling cylinders are run
out completely. The valve is located to the right of the attachment con-
trol valve on the sideshift frame's trailing edge under Valve block lev-
eling cylinders.
Passive leveling
The over-centre valves allow flow of hydraulic oil between right and left
leveling cylinders, from piston sides to rod sides, all according to an-
gle.
Active leveling
The over-centre valves close when the feed pressure is high enough
to put all leveling cylinders in bottom position. Then, hydraulic oil is
supplied through the leveling cylinder valve block to the rod sides on
one side's (right or left) cylinders and the side lifts. When leveling, the
other side will thus always be in its lowest position. This always gives
maximal leveling travel.
001062

110 7 Load handling – 7.8.6 Valve block levelling cylinders
7.8.6 Valve block levelling cylinders

Valve block levelling cylinders, description
page
–
The valve block for levelling cylinders leads pressure from the attach-
ment control valve to the levelling cylinders. The valve block contains
lock valves that block levelling when levelling lock is activated or if the
machine loses electrical power. The valve is located to the right of the
attachment control valve on the sideshift frame's trailing edge above
the over-centre valve levelling.
Lock valve
The lock valve is opened by Solenoid valve levelling (Y6034). When
the lock valve is closed the oil is blocked to and from the levelling cyl-
inders, and levelling is blocked. Solenoid valve levelling (Y6034) is
supplied with voltage by Control unit attachment option (D791-2) or-
Control unit attachment right leg pair (D791-4).
001061
7.8.7 Levelling cylinders

Levelling cylinders, description
page
–
On machines with hydraulic levelling there are four hydraulic cylinders

between the sideshift frame's parts, see Sideshift frame, description
page 111.
001860

page
–


page
–
The sideshift frame is available in two different versions, see Sideshift

1 2 3 4
frame, description page 53.
Mechanical levelling
The sideshift frame is larger than the attachment's main beam. The
main beam can move freely between the slide plates. This allows ap-
prox. 5 ° levelling.
001932
5 Hydraulic levelling
1. Main beam attachment The sideshift frame is split in two. There are four levelling cylinders be-
2. Sideshift frame upper section tween the two sections, see Levelling cylinders, description page 110.
3. Levelling cylinder The outer section is secured in the rotation yoke via the ring gear. The
4. Sideshift frame lower section inner part holds the attachment's main beam. The main beam slides
5. Sideshift cylinder on slide plates. The hydraulic cylinders' stroke makes levelling of the
main beam possible, approx. 5°. With hydraulically controlled levelling,
the angle of the main beam attachment can be controlled with the con-
trol lever.

page
–

page
–

112 7 Load handling – 7.9 Load carrying
7.9 Load carrying

7.9.1 Twistlocks
Twistlocks, function description
page
–

Alignment Full alignment or Tab 9 Frame, body, cab and accessories, group 9.1 Controls and instrumenta-
by-pass activated tion
Tab 8 Control system, group 8.2.2 By-passing
D1
2 1
D18
8 7, 20
5, 21
D790-1 D790-2 D795
D2
D797-R D791-1
4, 6, 13,18, 19
9
D13
D8 D3
14 3
17
C12
D17
P1 A
10 16
T1 B
C12 15
11
12
006890

1 Switch lock twistlocks (S1003) (automatic U = 24 V Tab 9 Frame, body, cab and accessories,
position) sends voltage signal to Control group 9.1 Controls and instrumentation
unit cab (D790-1). D1: Diagnostic menu, see section 8 Con-
trol and monitoring system, group 8.4.9.3
ATTACH, menu 3

7 Load handling – 7.9.1 Twistlocks 113

2 Control lever (S815-T2) sends voltage sig- US815/T2 = 24 V Tab 9 Frame, body, cab and accessories,
nal to Control unit cab (D790-1) to open group 9.1 Controls and instrumentation
twistlocks. D2: Diagnostic menu, see section 8 Con-
If Switch, lock twistlocks (S1003) is in trol and monitoring system, group 8.4.9.3
manual position no signal is needed from ATTACH, menu 3
control lever to open twistlock.
3 Sensor alignment left front (7202L), Sen- Sensor directly opposite Sensor alignment, description page 120
sor alignment right front (7202R), Sensor indicator plate: U = 24 V D3: Diagnostic menu, see section 8 Con-
alignment left rear (Y7203L) and Sensor trol and monitoring system, group 8.4.9.6
alignment right rear (Y7203R) send volt- ATTACH, menu 6
age signals to Control unit attachment
Control unit attachment (D791).
4 Control unit attachment (D791) sends Controlled by control and Tab 11 Common electric, group 11.5.3.5
alignment on the CAN bus. monitoring system, error Control unit attachment
5 Control unit KID (D795) activates event - Tab 11 Common electric, group 11.5.3.12
menu alignment. Control unit KID
6 Control unit attachment (D791) activates U = 24 V D18: Diagnostic menu, see section 8 Con-
the indicator light for alignment on the trol and monitoring system, group 8.4.9.10
boom's light panel. ATTACH, menu 10
7 Control unit KIT (D790-2) activates the in- - Tab 11 Common electric, group 11.5.3.11
dicator light for alignment on the cab's light Control unit KIT
panel.
8 Control unit cab (D790-1) sends open Controlled by control and Tab 11 Common electric, group 11.5.3.1
twistlocks or lock twistlocks on the CAN- monitoring system, error Control unit cab
bus. shown with error code.
9 Control unit frame rear (D797-R) activates U = 24 V Tab 11 Common electric, group 11.5.3.3
Solenoid valve, engagement of hydraulics Control unit frame rear
for top lift (Y6003). D8: Diagnostic menu, see section 8 Con-
HYD, menu 6
10 Solenoid valve, engagement of hydraulics - Valve block top lift hydraulics, description
for top lift (Y6003) opens and pressurizes page 46
valve block lift cylinder and sends load sig- D8: Diagnostic menu, see section 8 Con-
nal to hydraulic oil pump 2. trol and monitoring system, group 8.4.5.6
HYD, menu 6
11 The shuttle valve sends the strongest load - Tab 10 Common hydraulics, group 10.5.3
signal to the hydraulic oil pumps if several Shuttle valve
functions are activated simultaneously.
ment

114 7 Load handling – 7.9.1 Twistlocks

13 Control unit attachment (D791) activates U = 24 V Tab 11 Common electric, group 11.5.3.5
Servo valve open twistlocks (Y6039) or Control unit attachment
Servo valve lock twistlocks (Y6040). D12: Diagnostic menu, see section 8 Con-
ATTACH, menu 9
14 Servo valve open twistlocks (Y6039) or - Control valve attachment, description page
Servo valve lock twistlocks (Y6040) pres- 117
surizes the twistlock slide with servo pres- D12: Diagnostic menu, see section 8 Con-
sure. trol and monitoring system, group 8.4.9.9
ATTACH, menu 9
15 The control valve's twistlock spool chang- - Control valve attachment, description page
es position and pressurizes the lock cylin- 117
ders.
16 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 118
17 Sensor unlocked twistlocks (B7204) or Sensor directly opposite Sensor twistlocks, description page 121
Sensor locked twistlocks (B7205) sends indicator plate: U = 24 V D16: Diagnostic menu, see section 8 Con-
signal to Control unit attachment (D791). trol and monitoring system, group 8.4.9.7
ATTACH, menu 7
18 Control unit attachment (D791) supplies U = 24 V D18: Diagnostic menu, see section 8 Con-
voltage to Indicator light unlocked twist- trol and monitoring system, group 8.4.9.10
locks (H562) or Indicator light locked twist- ATTACH, menu 10
locks (H563) on the boom's light panel.
19 Control unit attachment (D791) sends in- Controlled by control and Tab 11 Common electric, group 11.5.3.5
formation about twistlocks unlocked or monitoring system, error Control unit attachment
twistlocks locked on the CAN-bus. shown with error code.
20 Control unit KIT (D790-2) supplies voltage - Tab 11 Common electric, group 11.5.3.11
to Indicator light unlocked twistlocks or In- Control unit KIT
dicator light locked twistlocks on the cab's
light panel.
menu twistlocks. Control unit KID

ling

7 Load handling – 7.9.1 Twistlocks 115
Overheight-legs, function description

page
–

Control switch Not activated Tab 11 Common electric, group 11.5.1.4 Manoeuvre switch voltage
Overload system Passive Tab 8 Control system, group 8.2.1.1 Mechanical overloading system
Twistlocks Open Twistlocks, function description page 112
13
1
2
D790-1
D797-R D791-2 7
3
8 12
D3
C6
P1
A
4 B 11
T1
10
9
C6 5
6
008218

1. Switch overheight legs (S1031) sends volt- U = 24 V Tab 9 Frame, body, cab and accesso-
age signal to Control unit cab (D790-1). ries, group 9.1 Controls and instrumen-
tation
2. Control unit cab (D790-1) sends message Controlled by control and Tab 11 Common electric, group 11.5.3.1
lower Overheight-legs on CAN-bus. monitoring system, error Control unit cab
3. Control unit frame rear (D797-R) activates U = 24 V Valve block top lift hydraulics, descrip-
Solenoid valve, engagement of hydraulics tion page 46
for top lift (Y6003). D3: Diagnostic menu, see tab 8 Control

116 7 Load handling – 7.9.1.1 Hydraulic oil pump

4. Solenoid valve, engagement of hydraulics - Valve block top lift hydraulics, descrip-
for top lift (Y6003) opens and pressurizes tion page 46
valve block top lift hydraulics and sends
load signal to hydraulic oil pump 2.
5. The shuttle valve and sends the strongest - Tab 10 Common hydraulics, group
load signal to hydraulic oil pump 2 if several 10.5.3 Shuttle valve
6. Hydraulic oil pump 2 pumps oil from the hy- See pressure plate on left Tab 10 Common hydraulics, group
draulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement
7. Control unit attachment option (D791-2) ac- U = 24 V Control valve attachment, description
tivates Servo valve overheight-legs up page 117
(Y6070) or Servo valve overheight-legs
down (Y6071).
8. Servo valve overheight-legs up (Y6070) or U = 24 V Control valve attachment, description

Servo valve overheight-legs down (Y6071) page 117
pressurizes over-centre valve overheight-
legs.
9. Over-centre valve opens and pressurizes - Over-centre valve (product alternative

hydraulic cylinder overheight-legs. Overheight-legs) page 122
10. Hydraulic cylinder overheight-legs lowers - Hydraulic cylinder overheight-legs page

the overheight legs. 122
11. Sensor overheight-legs up left (B7231-L) or Sensor right in front of in- Sensor overheight-legs page 123
Sensor overheight-legs up right (B7231-R) dicator plate: U = 24 V
sends voltage signal to Control unit attach-
ment option (D791-2).
12. Control unit attachment option (D791-2) ac- Overheight-legs up: U = Tab 11 Common electric, group 11.5.3.6
tivates Indicator light overheight-legs up 24 V Control unit attachment option
(H5001). Overheight-legs down: U
=0V
13 Indicator light overheight-legs up (H5001) is Overheight-legs up: U = Tab 9 Frame, body, cab and accesso-
on when the legs are completely raised. 24 V ries, group 9.1 Controls and instrumen-
Overheight-legs down: U tation
=0V
7.9.1.1 Hydraulic oil pump

page
–

7.9.1.2 Valve block top lift hydraulics

page
–

7 Load handling – 7.9.1.3 Control valve attachment 117
7.9.1.3 Control valve attachment

page
–
Twistlocks are controlled by a separate section in the attachment's

control valve. For a general description of the valve and component lo-
cation, see Control valve attachment, description page 47.
Twistlocks slide, description

The valve slide controls direction and the lock cylinder.
The valve slide is controlled by two servo valves, lock twistlocks and
open twistlocks.
Servo valve lock twistlocks, description

Servo valve lock twistlocks controls pressure to the twistlocks slide so
that the twistlocks slide opens and pressurises the lock cylinders.
Servo valve lock twistlocks is controlled electrically with Solenoid
valve lock twistlocks (Y6040) which is activated by Control unit, attach-
ment (D791-1). The servo valve directs servo pressure to the twist-
locks slide proportional to the control current to the solenoid valve.
Servo valve open twistlocks, description

Servo valve open twistlocks controls pressure to the twistlocks slide so
that the twistlocks slide opens and pressurises the lock cylinders.
Servo valve open twistlocks is controlled electrically with Solenoid
valve open twistlocks (Y6041) which is activated by Control unit, at-
tachment (D791-1). The servo valve directs servo pressure to the
twistlocks slide proportional to the control current to the solenoid
valve.

page
–
7.9.1.4 Shuttle valve

page
–

118 7 Load handling – 7.9.1.5 Lock cylinder
7.9.1.5 Lock cylinder

Lock cylinder, description
page
–
The lock cylinder turns the lock mechanism to rotate twistlocks. Two
lock cylinders, one in the right-hand and one in the left-hand spreader
beam turn the lock mechanism. The lock cylinders are located in the
centre of the spreader beam's longitudinal section.
000539

page
–
7.9.1.6 Lock mechanism

Lock mechanism, description
page
–
The lock mechanism transfers the lock cylinders' output to the twist-
locks. Two lock mechanisms, one in the right-hand and one in the left-
hand spreader beam act on the twistlocks. The lock mechanism runs
in the spreader beam's longitudinal section between the twistlocks.
The lock mechanism consists of a rod with linkages in the end. The rod
is secured in the levers which turn the twistlocks. There is an attaching
lug for the lock cylinder in the centre of the rod.
001863

7 Load handling – 7.9.1.7 Twistlocks 119
7.9.1.7 Twistlocks
Twistlocks, description
page
–
1
WARN IN G
Dropped load.
2 Fatal danger!
Twistlocks hold the load during load handling and

5 therefore it is very important that twistlocks are
checked according to instructions and are replaced at
the slightest sign of damage or wear.
4 3 Twistlocks secure the load and are located in the corners of the
spreader beam's logitudinal part.
Twistlocks are manufactured according to international standards in
high-strength steel. The lift pins are marked with serial numbers.
Twistlocks are connected in pairs via a link system to a hydraulic cyl-
inder which in turn is controlled via a section in the attachment's con-
trol valve. Inductive sensors send signals when twistlocks are locked
000536
and unlocked, respectively.
1. Lock mechanism
2. Sensor alignment
3. Alignment pin
4. Lift pin
5. Lock guide
Twistlock, replacement
page
–

3 Clean the twistlocks and the surrounding area.
4 Undo the centre nut for the twistlocks.
5 Tap the nut so that the lift pin releases from the wedge.
6 Hold the lift pin while the centre nut is removed.
WARN IN G
Twistlocks are heavy. Risk of crushing, product dam-
age.

120 7 Load handling – 7.9.1.8 Sensor alignment
7 Remove the centre nut and lift away the twistlock.

8 Place a new lift pin in the guide pin. Grease the lift pin with Lubri-
cating grease.
9 Place the lift pin in the guide pin in the extension beam. Place the
guide pin so that the grease cup is accessible through the holes
in the extension beam.
NOTE
Do not forget the washer between the extension beam and
the guide pin.
10 Fit the wedge, bearings, lever, new lock washers and new lock
nuts on the lock pin.
Brush on Lubricating grease on the parts before installing.
11 Check the positions of the parts and that the twistlock can move.
12 Tighten the lock nuts with torque, 300 Nm.
13 Grease the guide pin, lever, and bearing with Lubricating grease.
14 Check that the twistlock mechanism can move.
15 Turn on the main electric power and start the machine.
16 Check that the twistlock is working.
7.9.1.8 Sensor alignment

Sensor alignment, description
page
–
The sensor for alignment senses when the attachment has contact
with the container. Four inductive position sensors, one at each twist-
lock located in the corners of the spreader beam's longitudinal section,
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 over 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 spreader beam's lower edge. The clearance between the at-
tachment and the container's corner boxes results in the sensors stop
sending signals when the attachment is lifted.
trol unit attachment (D791) when the indicator pin is pressed in.
001451

7 Load handling – 7.9.1.9 Sensor twistlocks 121
Sensor alignment, checking

page
–

2 Check that the indicator pins in the corner boxes can move up
and down freely. The indictor pins must spring down when they
are not loaded.
3 Check that the sensor is free of damage and dirt.
4 Start the machine.
The illustration shows older versions of sensor mount-

ing.
5 Lower the attachment onto a container and check that all twist-
locks indicate alignment, filled circles in event menu alignment,
and that the indicator lamp alignment comes on.
6 Lift the attachment slightly so that the alignment just disappears
(unfilled circles in event menu alignment or indicator lamp align-
000360
ment goes out).

Event menu alignment 7 Check how large a movement on the indicator pins is required to
detect alignment. The movement must be 3–4 mm.
8 If necessary, adjust the position of the sensor, see Position sen-
sor, checking and adjustment page 5.

page
–
7.9.1.9 Sensor twistlocks

Sensor twistlocks, description
page
–
The twistlocks sensors sense when twistlocks are locked and un-
locked, respectively. Four inductive position sensors, two in each
spreader beam, sense the position of the lock mechanism. The sen-
sors are located by the lock cylinder in the middle of the spreader
beam's longitudinal section.
Both sides function in the same way independent of each other. On the
lock mechanism by the lock cylinder there is an indicator plate. When
the lock mechanism is in position for the twistlocks to be locked one of
the sensors sends a signal to Control unit, attachment Control unit at-
tachment (D791). When the lock mechanism is in position for the twist-
001452
locks to be unlocked the other sensor sends a signal to Control unit,

attachment Control unit attachment (D791). If the lock mechanism re-
mains in intermediate position then no signals are sent.
trol unit attachment (D791) when the indicator plate is in front of the
sensor.

page
–

122 7 Load handling – 7.9.1.10 Unloading valve attachment
7.9.1.10 Unloading valve attachment

page
–
7.9.1.11 Pipes and hoses

page
–
7.9.1.12 Overcentervalve
Over-centre valve (product alternative Overheight-legs)
page
–
1
The over-centre valve prevents the overheight-legs from lowering by
2 their dead weight.
3
008219
1. Hydraulic cylinder overheight-legs

2. Over-centre valve overheight-legs
3. Sensor overheight-legs up (B7231-L and B7231-R)
7.9.1.13 Hydraulic cylinder overheight legs

Hydraulic cylinder overheight-legs
page
–
1
The hydraulic cylinder lowers the overheight-legs. The hydraulic cylin-
2 der is controlled by a separate section in control valve attachment, see
Control valve attachment, description page 64.
3
008219


page
–

7 Load handling – 7.9.1.14 Sensor overheight legs 123
7.9.1.14 Sensor overheight legs

Sensor overheight-legs
page
–
1
Sensor overheight-legs up senses when the legs are completely
2 raised.
Sensor overheight-legs up left (B7231-L) senses the position of the left
3 leg pair and sends voltage signal to Control unit attachment option
(D791-2) when the leg pair is completely raised.
Sensor overheight-legs up right (B7231-R) senses the position of the
left leg pair and sends voltage signal to Control unit attachment option
(D791-2) when the leg pair is completely raised.
008219


page
–

124 7 Load handling – 7.9.2 Lift legs
7.9.2 Lift legs

Raising/lowering of front lift legs, function
page
–
description

20
25
1 D1 21, 22
D21
26, 27
A B A B A B A B A B
T1 D26
P1
19 24
2
D28 3, 18, 23
D790-1 D791-4 D18 D23
D797-R D791-3 D8 D13

3, 8, 13, 28
4
9 14
P1
T1
A B A B A B A B A B
D16
D4
D11 16, 17
5
15
6 11, 12
C7
7 10
006892

7 Load handling – 7.9.2 Lift legs 125

1 Switch lowering front legs (S1006) sends a U = 24 V Tab 9 Frame, body, cab and accessories,
voltage signal to Control unit cab (D790-1). group 9.1 Controls and instrumentation
D1: Diagnostic menu, see section 8 Con-
trol and monitoring system, group
8.4.11.1 COMBI, menu 1
2 Control unit cab (D790-1) sends front lift Controlled by control and Tab 11 Common electric, group 11.5.3.1
legs down or up on the CAN bus. monitoring system, error Control unit cab
3 Control unit attachment left legs (D791-3) Controlled by control and Tab 11 Common electric, group 11.5.3.7
and Control unit attachment right leg pair monitoring system, error Control unit attachment left legs and tab
(D791-4) send activate top hydraulics on shown with error code. 11 Common electric, group 11.5.3.8
the CAN bus. Control unit attachment right legs
4 Control unit frame rear (D797-R) activates U = 24 V Tab 11 Common electric, group 11.5.3.3
Solenoid valve, engagement of hydraulics Control unit frame rear
for top lift (Y6003). D4: Diagnostic menu, see tab 8 Control
5 Solenoid valve, engagement of hydraulics - Valve block top lift hydraulics, description
for top lift (Y6003) opens and pressurizes page 46
valve block lift cylinder and sends load sig- D4: Diagnostic menu, see tab 8 Control
nal to hydraulic oil pump 2. system, group 8.4.5.6 HYD, menu 6
6 The shuttle valve sends the strongest load - Tab 10 Common hydraulics, group
signal to the hydraulic oil pumps if several 10.5.3 Shuttle valve
7 Hydraulic oil pump 2 pumps oil from the hy- See pressure plate on left Tab 10 Common hydraulics, group
draulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement
8 Control unit attachment left legs (D791-3) U = 24 V Tab 11 Common electric, group 11.5.3.7
activates Solenoid valve front knee out left Control unit attachment left legs
(Y6056L). D8: Diagnostic menu, see section 8 Con-
8.4.11.1 COMBI, menu 10
9 Solenoid valve front knee out left (Y6056L) - Control valve lift legs, description page
pressurizes Hydraulic cylinder knee left 141
front. D8: Diagnostic menu, see section 8 Con-
8.4.11.1 COMBI, menu 10
10 Hydraulic cylinder knee left front lowers - Hydraulic cylinder knee/clamp, descrip-
Knee left front. tion page 146
11 Sensor front knee left (B7217L) sends volt- U = 24 V Sensor knee, description page 147
age signal to Control unit attachment left D11: Diagnostic menu, see section 8
legs (D791-3) when the knee is actuated. Control and monitoring system, group


12 Sensor front knee left (B7217L) stops send- U=0V Sensor knee, description page 147
ing signal to Control unit attachment left D12: Diagnostic menu, see section 8
legs (D791-3). Control and monitoring system, group
activates Solenoid valve front leg down left Control unit attachment left legs
(Y6013L) when Sensor front knee left D13: Diagnostic menu, see section 8
(B7217L) stops sending signal. Control and monitoring system, group
8.4.11.1 COMBI, menu 10
14 Solenoid valve front leg down left (Y6013L) - Control valve lift legs, description page
pressurizes Hydraulic cylinder leg left front. 141
D13: Diagnostic menu, see section 8
Control and monitoring system, group
8.4.11.1 COMBI, menu 10
15 Hydraulic cylinder leg left front lowers leg - Hydraulic cylinder leg, description page
left front. 149
16 Sensor front leg left (B7219L) sends a sig- U = 24 V Sensor lift leg, description page 149
nal to Control unit attachment left legs D16: Diagnostic menu, see section 8
(D791-3) when the leg is actuated. Control and monitoring system, group
17 Sensor front leg left (B7219L) stops send- U=0V Sensor lift leg, description page 149
ing a signal to Control unit attachment left D16: Diagnostic menu, see section 8
legs (D791-3). Control and monitoring system, group
18 Control unit attachment right leg pair U = 24 V Tab 11 Common electric, group 11.5.3.8
(D791-4) activates Solenoid valve front Control unit attachment right legs
knee out right (Y6056R) when Sensor front D18: Diagnostic menu, see section 8
leg left (B7219L) stops sending signal. Control and monitoring system, group
8.4.11.1 COMBI, menu 10
19 Solenoid valve front knee out right - Control valve lift legs, description page
(Y6056R) pressurizes Hydraulic cylinder 141
knee right front. D18: Diagnostic menu, see section 8
8.4.11.1 COMBI, menu 10
20 Hydraulic cylinder knee right front lowers - Hydraulic cylinder knee/clamp, descrip-
Knee right front. tion page 146
21 Sensor front knee right (B7217R) sends U = 24 V Sensor knee, description page 147
voltage signal to Control unit attachment D21: Diagnostic menu, see section 8
right leg pair (D791-4) when the knee is ac- Control and monitoring system, group
tuated. 8.4.11.1 COMBI, menu 4


22 Sensor front knee right (B7217L) stops U=0V Sensor knee, description page 147
sending signal to Control unit attachment D21: Diagnostic menu, see section 8
right leg pair (D791-4). Control and monitoring system, group
(D791-4) activates Solenoid valve front leg Control unit attachment right legs
down right (Y6013R) when Sensor front D23: Diagnostic menu, see section 8
knee right (B7217R) stops sending signal. Control and monitoring system, group
8.4.11.1 COMBI, menu 10
24 Solenoid valve front leg down right - Control valve lift legs, description page
(Y6013R) pressurizes Hydraulic cylinder 141
leg right front.
25 Hydraulic cylinder leg right front lowers leg - Hydraulic cylinder leg, description page
right front. 149
26 Sensor front leg right (B7219R) sends volt- U = 24 V Sensor lift leg, description page 149
age signal to Control unit attachment right D26: Diagnostic menu, see section 8
leg pair (D791-4) when the leg is lowered. Control and monitoring system, group
27 Sensor front leg right (B7219R) stops send- U=0V Sensor lift leg, description page 149
ing signal to Control unit attachment right D26: Diagnostic menu, see section 8
leg pair (D791-4) when the leg has reached Control and monitoring system, group
end-position. 8.4.11.1 COMBI, menu 4
(D791-4) activate Indicator light front leg Control unit attachment right legs
down (H580). D28: Diagnostic menu, see section 8
29 When the switch is released, activation of all solenoid valves stops. The solenoid valves remain activated even after
completed movement in order that it should be possible to complete the movement if the button is released when the
lift leg is in a middle position.

Raising/lowering of rear lift legs, function description

page
–

D32 32
20
31
21
1 D1 D21 22
D26 25
26 30 D30
27
A B A B A B A B A B
P1
T1
D23
24 19 29
2
3, 18, 23, 28 D18
D790-1 D791-4
D29
D797-R D791-3 3, 8, 13, 28 D8
4
D5 14 9 29
D13
P1
T1 A B A B A B A B A B
5 D16 16
17 30
15
C 6
11
D11 12
7 31
10 32
D32
006893


1 Switch rear legs (S1007) sends voltage U = 24 V Tab 9 Frame, body, cab and accessories,
signal to Control unit cab (D790-1). group 9.1 Controls and instrumentation
D1: Diagnostic menu, see section 8 Control
and monitoring system, group 8.4.11.1
COMBI, menu 1
2 Control unit cab (D790-1) sends rear lift Controlled by control and Tab 11 Common electric, group 11.5.3.1
legs down or up on the CAN bus. monitoring system, error Control unit cab
3 Control unit attachment left legs (D791- Controlled by control and Tab 11 Common electric, group 11.5.3.7
3) and Control unit attachment right leg monitoring system, error Control unit attachment left legs and tab 11
pair (D791-4) send activate top hydrau- shown with error code. Common electric, group 11.5.3.8 Control
lics on the CAN bus. unit attachment right legs
hydraulics for top lift (Y6003). D5: Diagnostic menu, see section 8 Control
and monitoring system, group 8.4.5.6 HYD,
menu 6
surizes valve block lift cylinder and D5: Diagnostic menu, see section 8 Control
sends load signal to hydraulic oil pump and monitoring system, group 8.4.5.6 HYD,
2. menu 6
neously.
ment
8 Control unit attachment left legs (D791- U = 24 V Tab 11 Common electric, group 11.5.3.7
3) activates Solenoid valve rear knee Control unit attachment left legs
out left (Y6058L). D8: Diagnostic menu, see section 8 Control
COMBI, menu 12
9 Solenoid valve rear knee out left - Control valve lift legs, description page 141
(Y6058L) pressurizes Hydraulic cylin- D8: Diagnostic menu, see section 8 Control
der knee left rear. and monitoring system, group 8.4.11.1
COMBI, menu 12
10 Hydraulic cylinder knee left rear lowers - Hydraulic cylinder knee/clamp, description
knee left rear. page 146


11 Sensor rear knee left (B7218L) sends U = 24 V Sensor knee, description page 147
voltage signal to Control unit attach- D11: Diagnostic menu, see section 8 Control
ment left legs (D791-3) when the knee and monitoring system, group 8.4.11.1
is actuated. COMBI, menu 5
12 Sensor rear knee left (B7218L) stops U=0V Sensor knee, description page 147
sending a signal to Control unit attach- D11: Diagnostic menu, see section 8 Control
ment left legs (D791-3). and monitoring system, group 8.4.11.1
COMBI, menu 5
13 Control unit attachment left legs (D791- U = 24 V Tab 11 Common electric, group 11.5.3.7
3) activates Solenoid valve rear leg Control unit attachment left legs
down left (Y6014L) when Sensor rear D13: Diagnostic menu, see section 8 Control
knee left (B7218L) stops sending sig- and monitoring system, group 8.4.11.1
nal. COMBI, menu 12
14 Solenoid valve rear leg down left - Control valve lift legs, description page 141
(Y6014L) pressurizes Hydraulic cylin- D13: Diagnostic menu, see section 8 Control
der leg left rear. and monitoring system, group 8.4.11.1
COMBI, menu 12
15 Hydraulic cylinder leg left rear lowers - Hydraulic cylinder leg, description page 149
leg left rear.
16 Sensor rear leg left (B7220L) sends U = 24 V Sensor lift leg, description page 149
ment left legs (D791-3) when the leg is and monitoring system, group 8.4.11.1
actuated. COMBI, menu 5
17 Sensor rear leg left (B7220L) stops U=0V Sensor lift leg, description page 149
sending signal to Control unit attach- D16: Diagnostic menu, see section 8 Control
ment left legs (D791-3) when Sensor and monitoring system, group 8.4.11.1
rear leg left (B7220L) stops sending sig- COMBI, menu 5
nal.
(D791-4) activates Solenoid valve rear Control unit attachment right legs
knee out right (Y6058R). D18: Diagnostic menu, see section 8 Control
COMBI, menu 12
19 Solenoid valve rear knee out right - Control valve lift legs, description page 141
(Y6058R) pressurizes Hydraulic cylin- D18: Diagnostic menu, see section 8 Control
der knee right rear. and monitoring system, group 8.4.11.1
COMBI, menu 12
20 Hydraulic cylinder knee/ right rear low- - Hydraulic cylinder knee/clamp, description
ers Knee right rear. page 146
21 Sensor rear knee right (B7218R) sends U = 24 V Sensor knee, description page 147
ment right leg pair (D791-4) when the and monitoring system, group 8.4.11.1
knee is actuated. COMBI, menu 5


22 Sensor rear knee right (B7218R) stops U=0V Sensor knee, description page 147
knee reaches its end position. COMBI, menu 5
(D791-4) activates Solenoid valve rear Control unit attachment right legs
leg out right (Y6014R) when Sensor D23: Diagnostic menu, see section 8 Control
rear knee right (B7218R) stops sending and monitoring system, group 8.4.11.1
signal. COMBI, menu 12
24 Solenoid valve rear leg down right - Control valve lift legs, description page 141
(Y6014R) pressurizes Hydraulic cylin- D23: Diagnostic menu, see section 8 Control
der leg right rear. and monitoring system, group 8.4.11.1
COMBI, menu 12
25 Hydraulic cylinder leg right rear lowers - Hydraulic cylinder leg, description page 149
leg right rear.
26 Sensor rear leg right (B7220R) sends U = 24 V Sensor lift leg, description page 149
leg is actuated. COMBI, menu 5
27 Sensor rear leg right (B7220R) stops U=0V Sensor lift leg, description page 149
ment right leg pair (D791-4). and monitoring system, group 8.4.11.1
COMBI, menu 5
28 When both rear lift legs are completely U = 24 V Tab 11 Common electric, group 11.5.3.7
lowered Control unit attachment left Control unit attachment left legs and tab 11
legs (D791-3) activates Solenoid valve Common electric, group 11.5.3.8 Control
operating position left (Y6053L) and unit attachment right legs
Solenoid valve clamping shut left D29: Diagnostic menu, see section 8 Control
(Y6054L). and monitoring system, group 8.4.11.1
At the same time Control unit attach- COMBI, menu 15 and 8.4.11.1 COMBI,
ment right leg pair (D791-4) activates menu 16
Solenoid valve operating position right
(Y6053R) and Solenoid valve clamping
right (Y6054R).
29 Solenoid valve operating position left - Control valve lift legs, description page 141
(Y6053L) closes the connection be- D29: Diagnostic menu, see section 8 Control
tween control valve and hydraulic cylin- and monitoring system, group 8.4.11.1
der clamping left front. COMBI, menu 15 and 8.4.11.1 COMBI,
Solenoid valve operating position right menu 16
(Y6053R) closes the connection be-
tween control valve and hydraulic cylin-
der clamping right front.


30 Solenoid valve clamping left (Y6054L) - Control valve lift legs, description page 141
pressurizes hydraulic cylinder clamp D30: Diagnostic menu, see section 8 Control
left rear. and monitoring system, group 8.4.11.1
Solenoid valve clamping right (Y6054R) COMBI, menu 15
pressurizes hydraulic cylinder clamp
right rear.
31 Hydraulic cylinder clamp presses knee - Hydraulic cylinder knee/clamp, description

down and thus presses the rear lift legs page 146
forward.
32 Sensor operating position left (B7212L) Sensor right in front of in- Sensor operating position, description page
sends voltage signal to Control unit at- dicator plate: U = 24 V 146
tachment left legs (D791-3) and Sensor D32: Diagnostic menu, see section 8 Control
operating position right B7212R) sends and monitoring system, group 8.4.11.1
voltage signal to Control unit attach- COMBI, menu 6
ment right leg pair (D791-4) when the
leg pair is in operating position.
33 When the switch is released, activation of all solenoid valves stops. The solenoid valves remain activated even after
completed movement in order that it should be possible to complete the movement if the button is released when
any lift leg is in a middle position.

Clamp with left legs, function description

page
–

Lift legs Lowered Raising/lowering of front lift legs, function description page 124
Raising/lowering of rear lift legs, function description page 128
22 20 15 14
17 22
D1
1
D22 D20 D17
P1 B A B A B A B A B A
D22
T1
D21
D12
13
2, 25 3, 12, 18, 21
D790-1 D791-4
D797-R D791-3 D795

4 3, 8, 23 24
9
D23 D4 D8
P1
T1
A B A B A B A B A B
D22
5
D22 D16
D19
6
7 22 19 16 22 006894
11 10

1 Switch clamp/release leg (S1008) sends U = 24 V Tab 9 Frame, body, cab and accessories,
voltage signal to Control unit, cab (D790- group 9.1 Controls and instrumentation
1). D1: Diagnostic menu, see section 8 Con-
COMBI, menu 1
2 Control unit cab (D790-1) sends clamp or Controlled by control and Tab 11 Common electric, group 11.5.3.1
release leg on the CAN bus. monitoring system, error Control unit cab


3 Control unit attachment left legs (D791-3) Controlled by control and Tab 11 Common electric, group 11.5.3.7
and Control unit attachment right leg pair monitoring system, error Control unit attachment left legs and tab 11
(D791-4) send activate top hydraulics on shown with error code. Common electric, group 11.5.3.8 Control
the CAN bus. unit attachment right legs
draulics for top lift (Y6003). D4: Diagnostic menu, see section 8 Con-
HYD, menu 6
rizes valve block lift cylinder and sends D4: Diagnostic menu, see section 8 Con-
load signal to hydraulic oil pump 2. trol and monitoring system, group 8.4.5.6
HYD, menu 6
several functions are activated simultane-
ously.
ment
activates Solenoid valve clamping left Control unit attachment left legs
(Y6054L) or Solenoid valve clamping re- D8: Diagnostic menu, see section 8 Con-
lease left (Y6055L). trol and monitoring system, group 8.4.11.1
COMBI, menu 15
9 Solenoid valve clamping left (Y6054L) or - Control valve lift legs, description page
Solenoid valve clamping release left 141
(Y6055L) pressurizes Hydraulic cylinder D8: Diagnostic menu, see section 8 Con-
clamping left front and Hydraulic cylinder trol and monitoring system, group 8.4.11.1
clamping left rear. COMBI, menu 15
10 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
front act on knee left front so that left lift page 146
legs clamp shut or release.
11 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lift page 146
(D791-4) activates Solenoid valve clamp- Control unit attachment right legs
ing right (Y6054R) or Solenoid valve D12: Diagnostic menu, see section 8 Con-
clamping release right (Y6055R). trol and monitoring system, group 8.4.11.1
COMBI, menu 15


13 Solenoid valve clamping left (Y6054L) or - Control valve lift legs, description page
Solenoid valve clamping release left 141
(Y6055L) pressurizes Hydraulic cylinder D12: Diagnostic menu, see section 8 Con-
clamping left front and Hydraulic cylinder trol and monitoring system, group 8.4.11.1
clamping left rear. COMBI, menu 15
14 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee/clamp, description
front act on knee left front so that left lift page 146
15 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lift page 146
16 Sensor clamping position front leg left U = 24 V Sensor clamping position, description
(B7215L) sends voltage signal to Control page 152
unit attachment left legs (D791-3). D16: Diagnostic menu, see section 8 Con-
COMBI, menu 2
17 Sensor clamping position front leg right U = 24 V Sensor clamping position, description
(B7215R) sends voltage signal to Control page 152
unit attachment right leg pair (D791-4). D17: Diagnostic menu, see section 8 Con-
COMBI, menu 2
(D791-4) activate Indicator light clamping Control unit attachment right legs
position front legs (H578). D21: Diagnostic menu, see section 8 Con-
COMBI, menu 8
19 Sensor clamping position rear leg left U = 24 V Sensor clamping position, description
(B7216L) sends voltage signal to Control page 152
unit attachment left legs (D791-3). D19: Diagnostic menu, see section 8 Con-
COMBI, menu 2
20 Sensor clamping position rear leg right U = 24 V Sensor clamping position, description
(B7216R) sends voltage signal to Control page 152
unit attachment right leg pair (D791-4). D20: Diagnostic menu, see section 8 Con-
COMBI, menu 2
(D791-4) activates Indicator light clamp- Control unit attachment right legs
ing position rear legs (H579). D21: Diagnostic menu, see section 8 Con-
COMBI, menu 8


22 When lift is started Sensor alignment front U = 24 V Tab 9 Frame, body, cab and accessories,
leg left (B7213L) and Sensor alignment group 9.1 Controls and instrumentation
rear leg left (B7214L) send signal to Con- D22: Diagnostic menu, see section 8 Con-
trol unit attachment left legs (D791-3). trol and monitoring system, group 8.4.11.1
Sensor alignment front leg right (B7213R) COMBI, menu 3
and Sensor alignment rear leg right
(B7214R) send signal to Control unit at-
tachment right leg pair (D791-4).
If it takes longer than 4 seconds between
the first sensor's signal until all sensors
send signals, the lift function is blocked.
activates the indicator light for alignment Control unit attachment left legs
for the lift leg in question. D23: Diagnostic menu, see section 8 Con-
COMBI, menu 7
menu alignment bottom lift. Control unit KID
25 When more than two sensors indicate Checked by control and Tab 8 Control system, group 8.2.5 Speed
alignment or clamping position, speed monitoring system, error limitation
limitation is activated. shown with error code.
Lift legs, checking and adjusting

page
–
If needed, the lift legs may have to be operated manually step by step
with the diagnostic menu Extra\Combi menu 17, see tab 8 Control sys-
tem, group 8.4.11.1 COMBI.
1 Start key in position I.

2 Check that all sensors have voltage. The light-emitting diode on
the sensor should be lit when the sensor indicates.
3 Check the distance between all sensors and their shoulder, the
distance should be 4±1 mm when the sensor is directly opposite
the lug.
Sensor knee and Sensor leg should only be active during the
movement, not in both end-positions.
4 Check that the attachment hangs vertically, adjust with the tilt
function as needed.
5 Lower all legs completely.

6 Check that the legs are vertical in the lateral direction.

7 If needed, adjust the position of the lowering cylinder's rod
mounting by turning the piston rod.
After adjusting, the shoulders for sensors may have to be fine-
tuned.
NOTE
Loosen the lock nuts at the piston head before adjusting.
8 Check the c-c measurement between right and left lift leg, the
90˚ 90˚ measurement should be approx. 4876 mm at the lower part of the
legs.
c-c = 4876 mm
008205
Attachment seen from the front

9 Run the lift legs to clamping position.
10 Check that the lift legs lean 8.0° against each other in the longi-
tudinal direction.
11 If needed, adjust the position of the clamping cylinder's rod
mounting by turning the piston rod.
After adjusting, the shoulders for sensor knee may have to be
fine-tuned.
NOTE
Loosen the lock bolts in the piston head before adjusting.
8,0˚ 8,0˚
007458
Clamping position, max. retracted legs

12 Run the legs apart from clamping position.

13 Check that the rear lift legs lean 1.5° outward (backward).
14 Check that the front lift legs lean 9.0° outward (forward).
9,0˚ 1,5˚
007459
Clamping position, max. extended legs

15 Press at the top on the rear lowering button, the rear lift legs
should go to operating position. (Run apart the clamping position
to go back to end-position to enable testing of operating position
again.)
16 Check that the lift legs stop at 1.0° inward (forward).
1,0˚
007460
Operating position, rear legs

17 Adjust the position by moving sensor clamping position side-

ways.
001856
Sensor operating position

18 Press in the alignment lug on one lift leg at a time and check that
each indicator light alignment works.
If the light does not come on when the lug is pressed in, check
the bulb and Sensor alignment, see Sensor alignment, descrip-
tion page 151.
008200
Indicator lights alignment

19 Press in the alignment surfaces on the front and rear lift legs, re-
spectively, and check that indicator light alignment clamping po-
sition for each leg pair works.
When both alignment surfaces are pressed in, the indicator light
for clamping position front and rear should be on.
If the light does not come on when the alignment surfaces are
pressed in, check the bulb and Sensor clamping position, see
Sensor clamping position, description page 152.
008201
Indicator lights clamping position

140 7 Load handling – 7.9.2.1 Hydraulic oil pump
20 Check that indicator light front legs lowered is on when the front
lift legs are lowered.
008202
Indicator light front legs down
21 Run up the front lift legs and check that Indicator light front legs
lowered goes off when the legs are raised and that Indicator light
front legs up is on when the front legs are completely raised.
22 Check that the work lights on the attachment switches between
lighting of twistlocks and lighting of lift legs on right and left side
when the rear lift legs are raised and lowered on each side.
008204
Indicator light front legs up

page
–

7.9.2.2 Valve block top lift hydraulics

page
–

7 Load handling – 7.9.2.3 Control valve lift legs 141
7.9.2.3 Control valve lift legs

Control valve lift legs, description
page
–
The lift legs are controlled by two control valves: one for left pair of legs
1 2 3 4 5 6 7 8 9 10 and one for right pair of legs. The control valves are controlled by sep-
arate control units, Control unit attachment left legs (D791-3) andCon-
23 trol unit attachment right leg pair (D791-4). The control valves are
11 located crosswise (left front and right rear, respectively) on the bracket
22
for the knee on the attachment's main beam.
12
21 The control valves are identical and have five sections each:
20 13 • Raising/lowering of front knee

• Raising/lowering of front leg
19 14
• Raising/lowering of rear knee
18
15 • Raising/lowering of rear leg
17 • Clamping position
16
The control valve is an electro-hydraulically controlled, proportional
and pressure compensated direction valve. Electrically controlled
pressure reducing valves convert electrical current to servo pressure.
The servo pressure controls the spring centred valve slides which con-
trol pressure and flow for the function in question. The valve slide has
a flow limit in order that several functions can be activated simultane-
ously.
000467
Valve slide front knee

1. Solenoid valve, rear knee out (Y6058) The valve slide controls the direction and speed of front knee lowering
2. Solenoid valve, rear knee in (Y6059) by controlling the hydraulic pressure to hydraulic cylinder knee and
3. Solenoid valve, clamping (Y6054) clamp.
4. Solenoid valve, clamping release (Y6055)
The valve slide is controlled by servo valve front knee out and servo
5. Solenoid valve, front knee in (Y6057)
valve front knee in.
6. Solenoid valve, front leg up (Y6060)
7. Solenoid valve, front leg down (Y6013)
Servo valve front knee out
8. Solenoid valve, front knee out (Y6056)
9. Drain to tank Servo valve front knee out, controls servo pressure to valve slide front
10. Connection, hydraulic cylinder for front leg knee so that it controls oil pressure for front knee out.
11. Connection, hydraulic cylinder for front knee Servo valve front knee is controlled electrically with Solenoid valve
12. Connection, hydraulic cylinder for front leg front knee out (Y6056) which is activated by Control unit attachment
13. Connection, hydraulic cylinder for front knee left legs (D791-3) or Control unit attachment right leg pair (D791-4),
14. Connection, hydraulic cylinder for clamping depending on if it is the right or left leg.
15. Connection, hydraulic cylinder for rear knee The signal can be checked from the diagnostic menu, see section 8
16. Connection, hydraulic cylinder for rear leg Control and monitoring system, group 8.4.11.1 COMBI, menu 10.
17. Feed from hydraulic oil pumps
18. Tank return (through filter) Servo valve front knee out
19. Connection, hydraulic cylinder for rear leg
Servo valve front knee in, controls servo pressure to valve slide front
20. Connection, hydraulic cylinder for rear knee
knee so that it controls oil pressure for front knee in.
21. Connection, hydraulic cylinder for clamping
22. Solenoid valve, rear leg down (Y6014) Servo valve front knee is controlled electrically with Solenoid valve
23. Solenoid valve, rear leg up (Y6061) front knee in (Y6057) which is activated by Control unit attachment left
legs (D791-3) or Control unit attachment right leg pair (D791-4), de-
pending on if it is the right or left leg.
Control and monitoring system, group 8.4.11.1 COMBI, menu 11.

142 7 Load handling – 7.9.2.3 Control valve lift legs
Valve slide front leg

The valve slide controls the direction and speed of front leg lowering
by controlling the hydraulic pressure to hydraulic cylinder leg.
The valve slide is controlled by servo valve front leg down and servo
valve front leg out.
Servo valve front leg down

Servo valve front leg down, controls servo pressure to valve slide front
leg so that it controls oil pressure leg lowering.
Servo valve front leg is controlled electrically with Solenoid valve front
leg down (Y6013) which is activated by Control unit attachment left
Servo valve front leg up

Servo valve front leg up, controls servo pressure to valve slide front leg
so that it controls oil pressure for leg raising.
Servo valve front leg is controlled electrically with Solenoid valve front
leg up (Y6060) which is activated by Control unit attachment left legs
(D791-3) or Control unit attachment right leg pair (D791-4), depending
on if it is the right or left leg.
Valve slide clamping

Valve slide clamping controls the direction and speed of clamping with
the leg pair by controlling the hydraulic pressure to hydraulic cylinder
knee and clamp.
The valve slide is controlled by servo valve clamping and servo valve
clamping release.
Servo valve clamping

Servo valve clamping, controls servo pressure to valve slide clamping
so that it controls oil pressure for clamping.
Servo valve clamping is controlled electrically with Solenoid valve
clamping (Y6054) which is activated by Control unit attachment left
pending on if it is the right or left pair of legs.

7 Load handling – 7.9.2.3 Control valve lift legs 143
Servo valve clamping release

Servo valve clamping release, controls servo pressure to valve slide
clamping position so that it controls oil pressure for clamping release.
Servo valve clamping release is controlled electrically with Solenoid
valve clamping release (Y6055) which is activated by Control unit at-
tachment left legs (D791-3) or Control unit attachment right leg pair
(D791-4), depending on if it is the right or left pair of legs.
Valve slide rear knee

The valve slide controls the direction and speed of rear knee lowering
by controlling the hydraulic pressure to hydraulic cylinder knee and
clamp.
The valve slide is controlled by servo valve rear knee out and servo
valve rear knee in.
Servo valve rear knee out

Servo valve rear knee out, controls servo pressure to valve slide rear
knee so that it controls oil pressure for knee out.
Servo valve rear knee out is controlled electrically with Solenoid valve
rear knee out (Y6058) which is activated by Control unit attachment
left legs (D791-3) or Control unit attachment right leg pair (D791-4),
depending on if it is the right or left knee.
Servo valve rear knee in

Servo valve rear knee in, controls servo pressure to valve slide knee
so that it controls oil pressure for knee in.
Servo valve rear knee in is controlled electrically with Solenoid valve
rear knee in (Y6059) which is activated by Control unit attachment left
pending on if it is the right or left knee.
Valve slide rear leg

The valve slide controls the direction and speed of rear leg lowering by
controlling the hydraulic pressure to hydraulic cylinder leg.
The valve slide is controlled by servo valve rear leg down and servo
valve rear leg out.

144 7 Load handling – 7.9.2.4 Shuttle valve
Servo valve rear leg down

Servo valve rear leg down, controls servo pressure to valve slide front
leg so that it controls oil pressure leg lowering.
Servo valve rear leg down is controlled electrically with Solenoid valve
rear leg down (Y6014) which is activated by Control unit attachment
left legs (D791-3) or Control unit attachment right leg pair (D791-4),
depending on if it is the right or left leg.
Servo valve rear leg up

Servo valve rear leg up, controls servo pressure to valve slide rear leg
so that it controls oil pressure for leg raising.
Servo valve rear leg up is controlled electrically with Solenoid valve
rear leg up (Y6061) which is activated by Control unit attachment left

page
–
7.9.2.4 Shuttle valve

page
–

7 Load handling – 7.9.2.5 Valve drive position 145
7.9.2.5 Valve drive position

Valve operating position, description
page
–
The valve for operating position cuts off the pressure to the front
clamping hydraulic cylinder. The valve is located on the attachment's
main beam by the hydraulic cylinder knee and clamp.
When the valve is activated, it cuts the hydraulic connection between
Control valve attachment lift legs and hydraulic cylinder knee and
clamp front. This results in only the rear lift leg being angled forward.
Solenoid valve operating position (Y6053L/R) is activated by Control
unit attachment left legs (D791-3) or Control unit attachment right leg
pair (D791-4) depending on whether it is the right or left leg.
001849
7.9.2.6 Main beam attachment

page
–
The brackets for knee and hydraulic cylinder knee and clamp are lo-
cated on the attachment's main beam.
7.9.2.7 Knee
Knee, description
page
–
The knee is located between the attachment's main beam and lift leg.
There are four knees, one at each lift leg. The knee enables folding in
and clamping with the legs. The knee is controlled by hydraulic cylin-
der knee and clamp.
Located on the knee joint is an indicator ring which is turned with the
lift leg. The indicator ring is used together with Sensor, knee, to deter-
mine whether the leg is raised, in intermediate position or lowered.
001851

146 7 Load handling – 7.9.2.8 Hydraulic cylinder knee and bracket
7.9.2.8 Hydraulic cylinder knee and bracket

Hydraulic cylinder knee/clamp, description
page
–
Hydraulic cylinder knee and clamp has two pistons in separate cylin-
1 2
ders. There are four hydraulic cylinders, one at each lift leg. The hy-
draulic cylinder is located between attachment and knee. One of the
hydraulic cylinder's pistons folds the knee joint out. The other piston
clamps with the lift legs by angling the knee joint further.
001852
1. Hydraulic cylinder, clamp

2. Hydraulic cylinder, knee

page
–
7.9.2.9 Sensor drive position

Sensor operating position, description
page
–
The sensor for operating position senses the position of the rear lift
legs' hydraulic cylinder for knee and clamp. This is used to indicate op-
erating position for the rear lift legs. There are two sensors, one on
each side (right and left).
Sensor, operating position left (B7212L/R) provides a voltage signal
when the rear hydraulic cylinder lowering knee/clamp is in its inner end
position. The signal is used to stop activation of the solenoid valve for
operating position when the rear lift leg is lowered.
001856

page
–

7 Load handling – 7.9.2.10 Sensor knee 147
7.9.2.10 Sensor knee

Sensor knee, description
page
–
Sensor knee senses the position of the knee joint, this is used to con-
trol lowering of the legs. There are four sensors, one by each knee.
Sensor front knee (B7217) and Sensor rear knee (B7218) give voltage
signals when the knee is between either end-position. The signal goes
to 0 V when end-position is reached. This applies both when retracting
and extending. The signal is used to activate the next step in the se-
quence. If the signal does not go to 0 V, the leg is not lowered.
Control and monitoring system, group 8.4.11.1 COMBI, menu 4–5.
001853

page
–

148 7 Load handling – 7.9.2.11 Lift legs
7.9.2.11 Lift legs

Lift legs description
page
–
The lift legs grip underneath around the load. On the lower ends of the
legs are lift shoes. The lift legs are raised and lowered with the hydrau-
lic cylinder lift leg.
Located on the lift leg joint is an indicator ring which is turned with the
lift leg. The indicator ring is used together with Sensor, leg, to deter-
mine whether the leg is raised, in intermediate position or lowered.
001866

7 Load handling – 7.9.2.12 Hydraulic cylinder legs 149
7.9.2.12 Hydraulic cylinder legs

Hydraulic cylinder leg, description
page
–
Hydraulic cylinder lift leg is located between knee and lift leg. The hy-
draulic cylinder raises and lowers the lift legs.
001855

page
–
7.9.2.13 Sensor lift legs

Sensor lift leg, description
page
–
Sensor lift leg senses the position of the lift leg. This is used to control
lowering of the legs. There are four sensors, one by each lift leg.
Sensor front leg (B7219) and Sensor rear lift leg (B7220) give voltage
signals when the lift legs are between either end-position. The signal
goes down to 0 V when end-position is reached. This applies both
when raising and lowering. The signal is used to activate the next step
in the sequence. If the signal doesn't go to 0 V, the knees are not ac-
tuated.
Control and monitoring system, group 8.4.11.1 COMBI, menu 4–5.
001859

page
–

150 7 Load handling – 7.9.2.14 Lifting shoe
7.9.2.14 Lifting shoe

Lift shoe, description
page
–
The lift shoe is located at the lower end of the lift legs. The lift shoe
grips under the load. At each lift shoes there are two sensors. Sensor
alignment senses when the lift shoe has contact with the load from
above, see Sensor alignment, description page 151. Sensor clamping
position senses when the lift shoe has horizontal contact with the load,
see Sensor clamping position, description page 152.
3
001857
1. Indicator pin, clamping position sensor

2. Indicator pin, alignment sensor
3. Lift shoe

7 Load handling – 7.9.2.15 Sensor alignment 151
7.9.2.15 Sensor alignment

Sensor alignment, description
page
–
The sensor for alignment (B7213L/R or B7214L/R) senses when the

lift shoe has contact with the load from above. The sensor is located
behind the lift shoe and senses the position on a linkage. The linkage
is affected by a pin in the middle of the lift shoe which is pressed down
1 when the load is positioned correctly in the lift shoe.
001858
1. Sensor, clamping position (B7215L/R or B7216L/

R)
2. Sensor, alignment (B7213L/R or B7214L/R)

page
–

152 7 Load handling – 7.9.2.16 Sensor clamping position
7.9.2.16 Sensor clamping position

Sensor clamping position, description
page
–
The sensor for clamping position (B7215L/R or B7216L/R) senses

when the lift shoe has horizontal contact with the load. The sensor is
located behind the lift shoe and is activated by a bolt mounted on a
spring-loaded plate on the lift shoe.
1
2
001858
1. Sensor, clamping position (B7215L/R or B7216L/

R)
2. Sensor, alignment (B7213L/R or B7214L/R)

page
–
7.9.2.17 Unloading valve attachment

page
–

page
–

7 Load handling – 7.10 Additional functions 153
7.10 Additional functions

7.10.1 Support jacks
Support jacks, function description
page
–

ue
Control switch Disengaged Tab 10 Common hydraulics, group 10.4.2 Axial piston pump with variable displace-
ment
Parking brake Released Tab 4 Brakes, group 4.5 Parking brake system
Transmission Neutral position Tab 2 Transmission
Machine sta- Speed = 0 km/h -

tionary
14
D1 D13
1
2, 13
D790-1 11
D795
D794 D797-O
4
D4 12
C8 D3
5
10 3
P
B
LS
7 T
C8 T1 A
8 6 9
004877

1 Switch support jacks (S1013) sends U = 24 V Tab 9 Frame, body, cab and accessories,
voltage signal to Control unit cab (D790- group 9.1 Controls and instrumentation
1). D1: Diagnostic menu, see section 8 Control
and monitoring system, group 8.4.11.3 SUP-
PORT-JACKS, menu 1

154 7 Load handling – 7.10.1 Support jacks

2 Control unit cab (D790-1) sends support Controlled by control Tab 11 Common electric, group 11.5.3.1
jacks up or down on CAN bus. and monitoring system, Control unit cab
error shown with error
code.
3 Sensor support jacks up (B7222) or Support jacks up or Sensor support jacks up, description page
Sensor support jacks down (B7021) down: U = 24 V 159
sends voltage signal to Control unit Support jacks in middle Sensor support jacks down, description page
frame option (D797-O). position: U = 0 V 160
D3: Diagnostic menu, see section 8 Control
and monitoring system, group 8.4.11.3 SUP-
PORT-JACKS, menu 2
4 Control unit frame option (D797-O) acti- U = 24 V Tab 11 Common electric, group 11.5.3.4
vates Solenoid valve support jacks Control unit frame option
down (Y6064) or Solenoid valve support D4: Diagnostic menu, see section 8 Control
jacks up (Y6063) and sends status for and monitoring system, group 8.4.11.3 SUP-
support jacks' position on the CAN-bus. PORT-JACKS, menu 3
5 Solenoid valve option frame down - Control valve option frame, description page
(Y6064) or Solenoid valve support jacks 155
up (Y6063) pressurizes the support jack D4: Diagnostic menu, see section 8 Control
slide in Control valve option frame. and monitoring system, group 8.4.11.3 SUP-
PORT-JACKS, menu 3
6 Control valve option frame sends load - Control valve option frame, description page
signal to shuttle valve option frame and 155
pressurizes valve block support jack cyl-
inder.
7 The shuttle valve sends pressure signal - Tab 10 Common hydraulics, group 10.5.3
on to hydraulic oil pump 1 & 2. Shuttle valve
8 Hydraulic oil pump 1 & 2 pump oil from See pressure plate on Tab 10 Common hydraulics, group 10.4.2 Ax-
the hydraulic oil tank. left frame beam. ial piston pump with variable displacement
9 Valve block support jacks pressurizes - Valve block support jacks, description page
hydraulic cylinder support jack. 160
10 Hydraulic cylinder lowers or raises the - Hydraulic cylinder support jacks, description
support jack. page 158
menu support jacks and blocks shifting Control unit KID
from neutral position.
12 Control unit engine (D794) sends en- Controlled by control Tab 11 Common electric, group 11.5.3.10
gine rpm on the CAN-bus. If the engine and monitoring system, Control unit engine
rpm is higher than 1000 rpm, then Con- error shown with error
trol unit cab (D790-1) activates automat- code.
ic lowering of support jacks.

7 Load handling – 7.10.1.1 Hydraulic oil pump 155

13 Control unit cab (D790-1) activates the U = 24 V Tab 11 Common electric, group 11.5.3.1
indicator light for support jacks down. Control unit cab
When support jacks are down, Control D13: Diagnostic menu, see section 8 Control
unit cab (D790-1) changes the load and monitoring system, group 8.4.11.3 SUP-
curve (limit for overload system). PORT-JACKS, menu 4
When support jacks are up, Control unit
cab (D790-1) allows shifting from neu-
tral position.

page
–

7.10.1.2 Control valve option frame

Control valve option frame, description
page
–
1
On machines with support jacks, movement of the support jacks is
controlled by a separate section in Control valve frame option. The
6 2
control valve is located on a bracket at the front of the engine compart-
ment.
5 3
The control valve is controlled by Control unit frame option (D797-O).
Control valve option frame is made up of several sections, each sec-
4 tion controls a function. The following functions are controlled by con-
trol valve option frame.
• Support jacks
• Sliding cab/Cab lift
• Cab tilt
The control valve is an electro-hydraulically controlled, proportional,
and pressure-compensating directional valve. Electrically controlled
000624
pressure reducing valves convert electric current to servo pressure.

The servo pressure controls spring-centred valve slides that control
1. Load signal (LS)
pressure and flow for the function in question. The valve slide has a
2. Pressure supply (P)
limitation of flow in order to enable activation of several functions at the
3. Tank return (T1)
same time.
4. Connection, steering cylinder (B)
5. Tank return (TP)
Valve slide support jacks
6. Connection, steering cylinder (A)
The valve slide controls the direction and speed of support jack lower-
ing by controlling the hydraulic pressure to hydraulic cylinder support
jacks.
The valve slide is controlled by servo valve support jacks up and servo
valve support jacks down.

156 7 Load handling – 7.10.1.2 Control valve option frame
Servo valve support jacks down

Servo valve support jacks up controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks up.
Servo valve support jacks down is controlled electrically with Solenoid
valve support jacks down (Y6064) which is activated by Control unit
frame option (D797-O).
Control and monitoring system, group 8.4.11.3 SUPPORT-JACKS,
menu 3.
Servo valve support jacks up

Servo valve support jacks down controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks down.
Servo valve support jacks up is controlled electrically with Solenoid
valve support jacks up (Y6063) which is activated by Control unit
frame option (D797-O).
menu 3.
Control valve option frame, changing

page
–
NOTE
Safety.

7 Load handling – 7.10.1.2 Control valve option frame 157
3 Mark up and detach the hydraulic hoses from the control valve.
1
NOTE
6 2 Plug all connections immediately to protect the hydraulic
5 3 4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
4
Remove the attaching bolts and lift away the valve. Place the
valve on a clean, protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and in place.
NOTE
000624
Transfer one part at a time so that the marking is not mixed

1. Load signal (LS)
up.
2. Pressure supply (P)
3. Tank return (T1) 7 Mark up the servo valves on the new control valve.
4. Connection, steering cylinder (B) 8 Fit the valve.
5. Tank return (TP)
9 Connect the wiring to the control valve in accordance with the
6. Connection, steering cylinder (A)
marking.
10 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE
11 Start the engine and check for leaks.
12 Check the function.
C AUTION
Activate the steering carefully and operate at the low-

est possible speed a couple of times to avoid cavita-
tion.

158 7 Load handling – 7.10.1.3 Hydraulic cylinder support jacks
C AUTION
Overfilling of oil, leakage, and environmental damage.

7.10.1.3 Hydraulic cylinder support jacks

Hydraulic cylinder support jacks, description
page
–
Hydraulic cylinder support jacks lowers the support jack up and down.
1 The hydraulic cylinder is located between support jacks and frame.
5
001870
7 6
1. Hydraulic cylinder, support jacks
2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Upper bracket
7. Sensor, support jacks down (B7221)

7 Load handling – 7.10.1.4 Support jacks 159
7.10.1.4 Support jacks

Support jacks, description
page
–
The support jack consists of linkage and support. The linkage is de-
1 signed so that it locks automatically when it is loaded from below in its
lowered position.
2 The support jack is secured in the frame and in the drive axle's attach-
ing bolts.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Upper bracket
7.10.1.5 Sensor raised support jacks

Sensor support jacks up, description
page
–
Sensor support jacks up (B7222) is located under hydraulic cylinder

1 support jacks and senses when the support jack is raised. There is a
sensor by each support jack. The sensor indicates when the support
jack is completely raised. This is used to control event menu support
2 jacks.
3 Control and monitoring system, group 8.4.11.3 SUPPORT-JACKS,
menu 2.
Sensor support jacks up (B7222) sends a voltage signal to Control unit
4
frame option (D797-O) when the support jack is completely raised.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket

160 7 Load handling – 7.10.1.6 Sensor lowered support jacks

page
–
7.10.1.6 Sensor lowered support jacks

Sensor support jacks down, description
page
–
Sensor support jacks down (B7221) is located under the support jack's
1 upper attachment and senses when the support jack is lowered. There
is a sensor by each support jack. This is used to control the support
jacks and activation of the indicator light support jacks down.
2
3 menu 2.
Sensor support jacks down (B7221) sends a voltage signal to Control
unit frame option (D797-O) when the support jack is completely low-
4
ered.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket

page
–

page
–
7.10.1.8 Shuttle valve option

Shuttle valve option, description
page
–
7.10.1.9 Valve block support jacks

Valve block support jacks, description
page
–
Valve block support jacks is located by the hydraulic cylinders and

contains a blocking valve which protects against accidental raising
and lowering of the support jacks.

7 Load handling – 7.10.2 Weight indicator 161
7.10.2 Weight indicator

Weight indicator, description
page
–
The weight indicator is available in two versions, fixed scale and dy-
namic scale. The fixed scale makes it possible to weigh the load with
boom and extension in a certain position. The dynamic scale shows
the load regardless of position of the boom and extension.
The weight indicator uses Sensor hydraulic pressure lift cylinder
(B768) and sensor boom angle to calculate the load. For more infor-
mation about sensors, see section 8 Control and monitoring system,
group 8.2.1 Overload protection.
The pressure sensor can be checked with diagnostic menu, see sec-
tion 8 Control and monitoring system, group 8.4.5.3 HYD, menu 3.
Fixed scale
The fixed scale weighs the load in a pre-set position on the boom by
measuring the pressure on the piston side in the lift cylinders. The
boom angle for the measuring position is indicated by a rod and mark-
ing on the left lift cylinder. The boom length for the measuring position
is indicated with an extra Sensor boom length (Position sensor boom
length 60 cm).
Dynamic scale
The dynamic scale weighs the load regardless of position. The weight
is calculated as a function of boom angle, boom length and the pres-
sure in the lift cylinders. The dynamic scale uses Sensor hydraulic
pressure lift cylinder, Sensor boom angle (analogue sensor) and Sen-
sor boom length (analogue sensor).

162 7 Load handling – 7.10.2 Weight indicator
Weight indicator, function description (product

page
–
alternative fixed scale)

1 D1
3, 4
2 7, 12
D790-1 D795
D797-R 11 D797-F D791-1

6 9
D5 D10 D10 D8
10
006896
5 >˚ Pa Pa 8

1 The pistol trigger on the control lever US815/T4 = 24 V Tab 9 Frame, body, cab and accessories,
sends voltage signal to Control unit cab group 9.1 Controls and instrumentation
(D790-1). D1: Diagnostic menu, see section 8 Con-
ATTACH, menu 2
2 Control unit cab (D790-1) sends weigh- Controlled by control and Tab 11 Common electric, group 11.5.3.1
ing activated on CAN-bus. monitoring system, error Control unit cab
3 Boom is lowered to measuring position - Lift and lower, function description page 11
(when the boom is in measuring position,
boom lowering is stopped automatically).
4 The boom is operated to 60 cm exten- - Extension, function description page 32

sion (when the boom is in measuring po-
sition, boom extension is stopped
automatically).
5 Sensor boom angle (B771) sends volt- U = 0,5-4,5 V Tab 8 Control system, group 8.2.1.5 Sen-
age signal proportional to boom angle to sor boom angle
Control unit frame rear (D797-R). D5: Diagnostic menu, see section 8 Con-
OP, menu
6 Control unit frame rear (D797-R) sends Controlled by control and Tab 11 Common electric, group 11.5.3.3
boom angle on the CAN-bus. monitoring system, error Control unit frame rear
shown with error code. D5: Diagnostic menu, see section 8 Con-
OP, menu

7 Load handling – 7.10.2 Weight indicator 163

menu fixed scale (flashing). Control unit KID
8 Sensor boom length 60 cm (B7224) U =24 V Tab 8 Control system, group 8.2.1.6 Sen-
sends signal to Control unit attachment sor boom length
(D791-1). D8: Diagnostic menu, see section 8 Con-
ATTACH, menu 5
9 Control unit attachment (D791-1) sends Controlled by control and Tab 11 Common electric, group 11.5.3.5
Boom length 60 cm on CAN-bus. monitoring system, error Control unit attachment
shown with error code. D8: Diagnostic menu, see section 8 Con-
ATTACH, menu 5
10 Sensor hydraulic pressure lift cylinder U = 0.5 - 4.5 V Sensor hydraulic pressure lift cylinder, de-
piston side left (B768-L1) and Sensor hy- scription page 28
draulic pressure lift cylinder piston side D10: Diagnostic menu, see section 8 Con-
right side (B768-R1) send voltage signal trol and monitoring system, group 8.4.10.3
to Control unit frame front (D797-F). OP, menu 3
11 Control unit frame front (D797-F) sends Controlled by control and Tab 11 Common electric, group 11.5.3.2
weight information on CAN-bus. monitoring system, error Control unit frame front
12 Control unit KID (D795) updates weight - Tab 11 Common electric, group 11.5.3.12
information in the display (fixed light). Control unit KID

164 7 Load handling – 7.10.2 Weight indicator
Weight indicator, function description (product

page
–
alternative dynamic scale)

8
D790-1 D795
D797-F D797-R
7 3,5
D6
D2 D4
6
006897
Pa Pa Pa Pa 2 m <˚ 4

1 Operating menu dynamic scale is select- - Tab 9 Frame, body, cab and accessories,
ed in the display. group 9.1 Controls and instrumentation
2 Sensor boom length (B777) sends volt- U = 0.5-4.5 V Tab 8 Control system, group 8.2.1.6 Sen-
age signal proportional to boom length to sor boom length
Control unit frame rear (D797-R). D2: Diagnostic menu, see section 8 Con-
OP, menu 4
boom length information on CAN-bus. monitoring system, error Control unit frame rear
4 Sensor boom angle (B771) sends voltage U = 0.5-4.5 V Tab 8 Control system, group 8.2.1.5 Sen-
signal proportional to boom angle to Con- sor boom angle
trol unit frame rear (D797-R). D4: Diagnostic menu, see section 8 Con-
OP, menu 4
boom angle information on CAN-bus. monitoring system, error Control unit frame rear

7 Load handling – 7.10.2.1 Sensor hydraulic pressure lifting cylinder 165

6 Sensor hydraulic pressure lift cylinder pis- U = 0.5-4.5 V Sensor hydraulic pressure lift cylinder, de-
ton side left (B768-12), Sensor hydraulic scription page 28
pressure lift cylinder rod side left (B768- D6: Diagnostic menu, see section 8 Con-
11), Sensor hydraulic pressure lift cylinder trol and monitoring system, group 8.4.10.3
piston side right (B768-10) and Sensor OP, menu 3
hydraulic pressure lift cylinder rod side
right (B768-13) send voltage signals pro-
portional to the hydraulic pressure in the
lift cylinders to Control unit frame front
(D797-F).
7 Control unit frame front (D797-F) calcu- Controlled by control and Tab 11 Common electric, group 11.5.3.2
lates and sends the weight on the CAN- monitoring system, error Control unit frame front
bus The weight is calculated with a ma- shown with error code.
chine-unique load curve based on sensor
values for boom angle, boom length, and
pressure in the lift cylinders.
NOTE
The load curve is unique to each ma-
chine.
8 Control unit KID (D795) shows weight in- - Tab 11 Common electric, group 11.5.3.12
formation in the display. Control unit KID
Printer, description
page
–
Printer is an option to the function dynamic scale that makes it possible

to save weights and print out lists of saved weights.
The printer is connected to Control unit KID (D795) and is located on
the instrument panel on the right side of the steering wheel.
The printer is controlled via Operating menu printer in the display,
where the operator selects which weights shall be saved and what is
to be printed.
004907
Position printer
7.10.2.1 Sensor hydraulic pressure lifting

cylinder
Sensor hydraulic pressure lift cylinder, general
page
–
See Sensor hydraulic pressure lift cylinder, description page 28.

166 7 Load handling – 7.10.2.2 Sensor boom angle
7.10.2.2 Sensor boom angle

Sensor boom angle, general
page
–

boom angle.
7.10.2.3 Sensor boom length

Sensor boom length, general
page
–

boom length.

7 Load handling – 7.10.3 Container counter 167
7.10.3 Container counter

Container counter, description
page
–
The container counter counts the number of lifted containers. The

counter has two counting units that can be reset separately. The con-
tainer counter counts in different ways depending on if top lift (twist-
locks) or bottom lift (lift legs) is used.
Top lift
The container counter counts lift when alignment disappears with
locked twistlocks and twistlocks do not open within 8 seconds.
Bottom lift
The container counter counts lift when the clamping function is activat-
ed and lift is started, and release of clamping position is not activated
within 10 seconds.
Container counter, function description (product

page
–
alternative top lift)

1, 4, 7
D1
10
D790-1 D795
D797-R D791-1
3, 6, 9
D5
D2
2, 8 5
006898

168 7 Load handling – 7.10.3 Container counter

1 The attachment is positioned over a con- - Lift and lower, function description page
tainer with the functions 7.2 Lift and lower 11
as well as 7.3 Extension. Extension, function description page 32
D1: Diagnostic menu, see section 8 Con-
BOOM, menu 1
2 Sensor alignment left front (7202L), Sen- Sensor directly opposite Sensor alignment, description page 120
sor alignment right front (7202R), Sensor indicator plate: U = 24 V D2: Diagnostic menu, see section 8 Con-
alignment left rear (Y7203L) Sensor align- trol and monitoring system, group 8.4.9.6
ment right rear (Y7203R) send voltage sig- ATTACH, menu 6
nal to Control unit attachment (D791-1).
alignment on CAN-bus. monitoring system, error Control unit attachment
4 Twistlocks are turned to locked position - Twistlocks, function description page 112
and close with the function 7.9.1 Twist-
locks.
5 Sensor locked twistlocks left (B7205L) and Sensor directly opposite Sensor twistlocks, description page 121
Sensor locked twistlocks right (B7205R) indicator plate: U = 24 V D5: Diagnostic menu, see section 8 Con-
send voltage signal to Control unit attach- trol and monitoring system, group 8.4.9.7
ment (D791-1). ATTACH, menu 7
locked twistlocks on CAN-bus. monitoring system, error Control unit attachment
7 The container is lifted with the function 7.2 - Lift and lower, function description page
Lift and lower. 11
8 Sensor alignment left front (7202L), Sen- U=0V Sensor alignment, description page 120
sor alignment right front (7202R), Sensor D2: Diagnostic menu, see section 8 Con-
alignment left rear (Y7203L) Sensor align- trol and monitoring system, group 8.4.9.6
ment right rear (Y7203R) stop sending ATTACH, menu 6
voltage signal toControl unit attachment
(D791-1).
9 Control unit attachment (D791-1) sends no Controlled by control and Tab 11 Common electric, group 11.5.3.5
alignment on CAN-bus. monitoring system, error Control unit attachment
10 If twistlocks remain locked for 8 seconds - Tab 11 Common electric, group 11.5.3.1
then Control unit cab (D790-1) counts up a Control unit cab
lift for the container counter.

7 Load handling – 7.10.3 Container counter 169
Container counter, function description (product

page
–
alternative bottom lift)

Control switch Disengaged Section 11 Common electrical, group 11.5.1.4 Control breaker voltage (15E)
1 3 4
2, 7
D4
D3
D1
D2
10
D790-1 D795
6, 9 D791-3 D791-4 6, 9
D5 D8 D5
5 8 5 8 D8
006899
1 The attachment's rear lift legs are - Raising/lowering of rear lift legs, function descrip-
lowered to operating position with tion page 128
the function 7.9.2 Lift legs. D1: Diagnostic menu, see section 8 Control and
monitoring system, group 8.4.11.1 COMBI, menu
1
2 The attachment is positioned over a - Lift and lower, function description page 11
container with the functions 7.2 Lift Extension, function description page 32
and lower as well as 7.3 Extension.
D2: Diagnostic menu, see section 8 Control and
monitoring system, group 8.4.8.1 BOOM, menu 1
3 The front lift legs are lowered with - Raising/lowering of front lift legs, function descrip-
the function 7.9.2 Lift legs. tion page 124
D3: Diagnostic menu, see section 8 Control and
monitoring system, group 8.4.11.1 COMBI, menu
1
4 The lift legs clamp around the con- - Clamp with left legs, function description page 133
tainer with the function 7.9.2 Lift D4: Diagnostic menu, see section 8 Control and
legs. monitoring system, group 8.4.11.1 COMBI, menu
1

170 7 Load handling – 7.10.3 Container counter

5 Sensor clamping position front leg Sensor directly opposite Sensor clamping position, description page 152
left (B7215L) and Sensor clamping indicator plate: U = 24 V D5: Diagnostic menu, see section 8 Control and
position rear leg left (B7216L) send monitoring system, group 8.4.11.1 COMBI, menu
voltage signal to Control unit at- 2
tachment left legs (D791-3).
Sensor clamping position front leg
right (B7215R) and Sensor clamp-
ing position rear leg right (B7216R)
send voltage signal to Control unit
attachment right leg pair (D791-4).
6 Control unit attachment left legs Controlled by control Tab 11 Common electric, group 11.5.3.7 Control
(D791-3) and Control unit attach- and monitoring system, unit attachment left legs
ment right leg pair (D791-4) send error shown with error Tab 11 Common electric, group 11.5.3.8 Control
clamping position lift legs on CAN- code. unit attachment right legs
bus.
7 The container is lifted with the func- - Lift and lower, function description page 11
tion 7.2 Lift and lower.
8 Sensor alignment front leg left Sensor directly opposite Sensor alignment, description page 151
(B7213L) and Sensor alignment indicator plate: U = 24 V D8: Diagnostic menu, see section 8 Control and
rear leg left (B7214L) send voltage monitoring system, group 8.4.11.1 COMBI, menu
signal to Control unit attachment 3
left leg pair (D791-3).
Sensor alignment front leg right
(B7213R) and Sensor alignment
rear leg right (B7214R) send volt-
age signal to Control unit attach-
ment right leg pair (D791-4).
9 Control unit attachment (D791-1) Controlled by control Tab 11 Common electric, group 11.5.3.5 Control
sends alignment on CAN-bus. and monitoring system, unit attachment
error shown with error
code.
10 If clamping position remains to be - Tab 9 Frame, body, cab and accessories, group
active for 10 seconds then Control 9.1 Controls and instrumentation
unit cab (D790-1) counts up one
bottom lift for the container counter.

7 Load handling – 7.10.4 Synchronous lift 171
7.10.4 Synchronous lift

Synchronous lift, function description
page
–

By-passed or boom height Tab 8 Control system, group 8.2.4 Height limitation
lower than height limitation
Height limitation
D1
+
2, 6
D790-1 D795
5 D797-R D797-F
D3 D4
006900
3 m <˚ 4

1 The control lever for lift or lower Lower: US815/P1 = 0.5–2.0 V Tab 9 Frame, body, cab and accessories,
and pistol trigger send voltage to group 9.1 Controls and instrumentation
Lift: US815/P1 = 3.0–4.5 V
Control unit cab (D790-1). D1: Diagnostic menu, see section 8 Control
Pistol trigger: US815/T4 = 24 V
and monitoring system, group 8.4.8.1 BOOM,
menu 1 and 8.4.9.2 ATTACH, menu 2
2 Control unit cab (D790-1) sends Controlled by control and Tab 11 Common electric, group 11.5.3.1 Con-
synchronized lift on CAN-bus. monitoring system, error trol unit cab
3 Sensor boom angle (B771) sends U = 0.5-4.5 V Tab 8 Control system, group 8.2.1.5 Sensor
voltage signal to Control unit boom angle
frame rear (D797-R). D3: Diagnostic menu, see section 8 Control
and monitoring system, group 8.4.10.1 OP,
menu 1
4 Sensor boom length (B777) sends U = 0.5-4.5 V Tab 8 Control system, group 8.2.1.6 Sensor
voltage signal to Control unit boom length
frame rear (D797-R). D4: Diagnostic menu, see section 8 Control
and monitoring system, group 8.4.10.4 OP,
menu 4

172 7 Load handling – 7.10.4 Synchronous lift

5 Control unit frame rear (D797-R) Controlled by control and Tab 11 Common electric, group 11.5.3.3 Con-
sends length and angle informa- monitoring system, error trol unit frame rear
tion on CAN-bus. shown with error code.
6 Control unit cab (D790-1) controls - Lift and lower, function description page 11
activates functions 7.2 Lift and Extension, function description page 32
lower as well as 7.3 Extension at
the same time so that the lifting
movement becomes vertical.

8 Control system 1
8 Control system
Table of Contents 8 Control system

mm mm mm mm mm mm
8 Control system ............................................................................................... 3

8.1 Controls and instrumentation ..................................................................... 4
8.1.4 Switch by-passing of load centre limitation and height limitation ........... 4
8.1.10 Error code menu .................................................................................... 4
8.2 Monitoring ................................................................................................... 7
8.2.1 Overloading system ............................................................................... 7
8.2.2 By-passing ........................................................................................... 15
8.2.3 Load centre limitation ........................................................................... 15
8.2.4 Height limitation ................................................................................... 16
8.2.5 Speed limitation ................................................................................... 16
8.2.6 Service indicator .................................................................................. 17
8.4 Diagnostics ............................................................................................... 18
8.4.1 CAN/POWER ....................................................................................... 20
8.4.2 LIGHTS ................................................................................................ 39
8.4.3 CAB ..................................................................................................... 50
8.4.4 CLIMATE ............................................................................................. 58
8.4.5 HYD ..................................................................................................... 65
8.4.6 ENGINE ............................................................................................... 69
8.4.7 TRANSM .............................................................................................. 76
8.4.8 BOOM .................................................................................................. 88
8.4.9 ATTACH .............................................................................................. 94
8.4.10 OP ...................................................................................................... 115
8.4.11 EXTRA ............................................................................................... 120
8.4.13 RMI .................................................................................................... 147
8.5 Setup ...................................................................................................... 150
8.5.1 Initiation ............................................................................................. 150
8.5.2 Calibration .......................................................................................... 176

2 8 Control system

Kalmar DRF 450 Load Handling

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7 Load handling 1

Table of Contents 7 Loadhandling

Workshop manual DRF 400–450 VDRF03.01GB

7.5.2 Valve block top lift hydraulics ............................................................... 64

VDRF03.01GB Workshop manual DRF 400–450

7.8.10 Pipes and hoses ................................................................................ 111

Workshop manual DRF 400–450 VDRF03.01GB

VDRF03.01GB Workshop manual DRF 400–450

Position sensor, checking and

1. Sensor, boom length 5. Sensor, twistlocks 13. Sensor, clamping position

3. Sensor, alignment 7. Sensor, damping 11. Sensor, lift leg

Workshop manual DRF 400–450 VDRF03.01GB

1 Machine in service position, see tab B Safety.

VDRF03.01GB Workshop manual DRF 400–450

7.1 Controls and instrumentation

left (boom in). See Extension, function description page 32.

Workshop manual DRF 400–450 VDRF03.01GB

When the potentiometer (position 7) is pressed down at the top edge,

When the potentiometer rotation (position 3) is pressed down on the

When switch (position 2) is pressed down, levelling lock is activated.

The pistol trigger (position 8) activates weighing if the machine is

VDRF03.01GB Workshop manual DRF 400–450

If lift is activated at the same time as the pistol trigger is pressed

7.1.2 Switch lock twistlocks

Switch lock twistlocks (S1001) controls locking of twistlocks. The

7.1.3 Switch automatic spreading

Switch automatic spreading (S1012) activates automatic spreading.

Control and monitoring system, group 8.4.9.4 ATTACH, menu 4.

Workshop manual DRF 400–450 VDRF03.01GB

7.1.5 Switch stop at 30' or 35'

VDRF03.01GB Workshop manual DRF 400–450

Condition Reference value Reference

Alignment Boom down: no alignment Twistlocks, function description page 112

D797-F D797-R 13, 18

Workshop manual DRF 400–450 VDRF03.01GB

Pos Explanation Signal description Reference

0.5 V is the fastest lowering

VDRF03.01GB Workshop manual DRF 400–450

Pos Explanation Signal description Reference

17 Regeneration UB768-L1/1 = 5 V Sensor hydraulic pressure lift cylinder, de-

Workshop manual DRF 400–450 VDRF03.01GB

Pos Explanation Signal description Reference

22 Damping - Tab 8 Control system, group 8.2.1.5 Sen-

Hydraulic diagram basic machine

Lowering speed, checking

The machine may absolutely not be used before the

7.2.1 Hydraulic oil pump

See section 10 Common hydraulics, group 10.4.2 Axial piston pump

VDRF03.01GB Workshop manual DRF 400–450

7.2.2 Servo filter

7.2.3 Pressure reducer

2 Servo pressure is stored in an accumulator. A built-in non-return valve

1. Accumulator servo pressure

Workshop manual DRF 400–450 VDRF03.01GB

Servo pressure, checking and adjusting

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

˚C 2 Machine in service position, see tab B Safety.