2 Transmission – Control system transmission 2:7

2.8 Control system transmission

Transmission, calibration

DANGER
Do not leave the machine during calibration. The
machine may start to move.

1 Check the transmission oil level, see Oil level, check, page 2:6.

10:23
2 In order to select the function to calibrate, navigate first to the
CUSTOMER SETTI NGS menu for service and settings with or and confirm with .

0
014981

10:23 3 Enter diagnostic code 1111 or . Confirm each digit with .

The code is obtained from Cargotec Support.
WRI TE PI N CODE
0
NOTE
The code determines which service menus are activated.
0 0
015625

4 Select 2. TRANSMISSION by scrolling with or and confirm

* SETTI NGS & DI AGNOSTI CS*
with .
2 . TRANSMI SSI ON
015623

5 Select 2.8 Transmission Control Sys by scrolling with or and

* 2 . TRANSMI SSI ON *
confirm with .
2.1 Controls & I n s t r u me n t s
2.2 Torque Conv & Cl u t c h Sy s
2.3 Mechanical T r a n s mi s s i o n
2.4 Hydraulic Tr a ns mi s s i o n
2.5 Electrical T r a n s mi s s i o n
2.6 Lubrication Sys t e m
2.7 Cooling syst em
2.8 Transmission Co n t r ol Sy s
015627

Maintenance Manual DRG 420-450 UDRG01.01GB

2:8 2 Transmission – Control system transmission

6 Select CALIBRATE by scrolling with or and confirm with .

* 2 . TRANSMI SSI ON *
DIAGNOSE INITIATE CALIBRATE
2.1 Controls & I n s t r u me n t s
2.2 Torque Conv & Cl u t c h Sy s
2.3 Mechanical T r a n s mi s s i o n
2.4 Hydraulic Tr a ns mi s s i o n
2.5 Electrical T r a n s mi s s i o n
2.6 Lubrication Sys t e m
2.7 Cooling syst em
2.8 Transmission Co n t r ol Sy s

015626
7 2.8 Request Heat mode is a function for heating the transmission
when the machine is stationary by braking the machine and
allowing the converter to heat the transmission oil.
Request heat mode
Status for heating.
0. Heating not in progress.
1. Heating in progress.
Target gearbox temperature
Indicates the lowest temperature the transmission should maintain
during calibration.
Actual gearbox temperature
Indicates the current temperature.
Heat up completed
Specifies whether the heating is completed.
0. Heating required.
1. Heating completed.
Actual engine speed
Current engine speed.
Actual gear
Specifies the gear that is activated -3 – +5. 0 indicates
transmission in neutral while + before gear value indicates forward
and - indicates backward.
8 If necessary, increase the oil temperature in the transmission as
follows:
A. Start Gearbox heat mode by pressing .
B. Move the gear selector to neutral without depressing the brake
pedal. The parking brake is then still active.
C. Select direction of travel forward or backward and apply half
to full throttle for 30 seconds.
D. Engage neutral position and apply half throttle for 15 seconds,
run the engine at idle.
E. Repeat steps C and D until the oil is warm.
When the temperature is correct Heat up completed changes from
0 to 1.

NOTE
During this warming-up procedure, it is possible that the
temperature out from the converter exceeds the limit value. This
is a result of heating the transmission using this rapid procedure.
Set the transmission in neutral and rev the engine to approx.
1300 rpm for about one minute in order to cool the transmission.
This means that the heat in the converter can be evacuated.
After one or two minutes the warming-up procedure can be
resumed, if the transmission temperature has not yet reached
70 °C.

9 Select Gearbox Calibration 2/2 by pressing .

UDRG01.01GB Maintenance Manual DRG 420-450

2 Transmission – Control system transmission 2:9

10 2.8 Request Calibration is a function to calibrate the transmission.

Request calibration
Status for calibration.
0. Calibration not in progress.
1. Calibration in progress.
AEB main code
Indicates which component is being calibrated or, in the event of a
fault, which component could not be calibrated, see table Tabell
Main code (AEB main code), page 2:10.
AEB cycle number
Specifies the current calibration cycle 0-255.
AEB sub code
Specifies action in the event of a fault during calibration, see table
Tabell Subcode (AEB SUB CODE), page 2:10.
Error code
Indicates active error codes for the transmission, see Workshop
manual for an explanation of the error codes.
Actual engine speed
Current engine speed.
11 Activate the parking brake. Start calibration by pressing .
Request operation changes the digit 0 to 1 and calibration starts.
The transmission will activate all gears during calibration.

NOTE
If the machine starts to move during calibration then use the
footbrake to keep the machine stationary.

DANGER
It is forbidden to leave the operator's station until
calibration is complete.
Fatal danger!
The machine may start to move and you must be
prepared to immediately stop calibration or brake the
machine.

IMPORTANT
Calibration can be cancelled at any time by moving the
gear selector to the opposite travel direction, exiting
the menu, releasing the parking brake or switching off
the machine. The transmission control unit will then
be reset and ignore the calibration results obtained
thus far.

• If calibration is performed without problems the display shows

main code (AEB main code) number 7, which means that the
calibration is finished, see table Tabell Main code (AEB main
code), page 2:10.
• If an error is identified during calibration the display shows a
main code (AEB main code) with a number between 8 and 15
for component, see table Tabell Main code (AEB main code),
page 2:10 and a subcode (AEB sub code) for action with a
number between 1 and 8. Follow instructions in table Subcode

Maintenance Manual DRG 420-450 UDRG01.01GB

2:10 2 Transmission – Control system transmission

(AEB sub code) for the identified subcode, see table Tabell
Subcode (AEB SUB CODE), page 2:10.

Tabell Main code (AEB main code)

Code Explanation
0. AEB mode not selected.
1. AEB mode selected, calibrating K1.
2. AEB mode selected, calibrating K2.
3. AEB mode selected, calibrating K3.
4. AEB mode selected, calibrating K4.
5. AEB mode selected, calibrating KV.
6. AEB mode selected, calibrating KR.
7. AEB mode selected, calibration finished.
8. AEB mode selected, calibration cancelled.
9. AEB mode selected, calibration cancelled when adjusting
K1.
10. AEB mode selected, calibration cancelled when adjusting
K2.
11. AEB mode selected, calibration cancelled when adjusting
K3.
12. AEB mode selected, calibration cancelled when adjusting
K4.
13. AEB mode selected, calibration cancelled when adjusting
KV.
14. AEB mode selected, calibration cancelled when adjusting
KR.
15. AEB mode selected, calibration cancelled when adjusting
WK.
16. AEB mode selected, calibrating WK.

Tabell Subcode (AEB SUB CODE)

Code Action
1. Shut down and restart the machine if the error code is "0".
Repeat the calibration. If the fault persists, the transmission
may need to be inspected.
2. Switch off and start the machine. Check that the travel
direction lever is in neutral position. Repeat calibration.
3. Switch off and start the machine. Check that the parking
brake is applied. Repeat calibration.
4. Switch off and start the machine. Test the parking brake. If
the parking brake works satisfactorily, repeat calibration. If
the parking brake does not work satisfactorily, service the
parking brake. Repeat calibration.
5. Switch off and start the machine. Let the transmission reach
working temperature. Repeat calibration.
6. Let the transmission oil cool by allowing the engine to idle in
neutral. When the oil has cooled, Control unit, transmission
(D7930) will resume the calibration.

UDRG01.01GB Maintenance Manual DRG 420-450

2 Transmission – Control system transmission 2:11

Code Action
7. Increase engine speed. Control unit, transmission (D7930)
will resume the calibration when the rpm is within specified
interval.
8. Decrease engine speed. Control unit, transmission (D7930)
will resume the calibration when the rpm is within specified
interval.

12 When the engine speed decreases to idling and AEB main code =
7 then calibration is complete.
13 Switch off the ignition with the ignition key lock and leave the
ignition switched off for at least 30 seconds in order to store the
values.

Maintenance Manual DRG 420-450 UDRG01.01GB

 8 Control system – Load sensors 8:13

Pos Explanation Signal description Reference

6 Control unit KFU (D7971) calculates and Checked by control 11.5.3.4 KFU control unit (D7971), page
sends the weight on the CAN bus. The system, error shown with 11:31
weight is calculated by a machine-unique error code.
load curve based on sensor values for
boom angle, boom length and pressure
in the lift cylinders.

NOTE
The load curve is unique for each
machine.

7 Control unit KID (D7950) shows weight - 11.5.3.3 Control unit, KID (D7950), page
information in the display. 11:29

Load sensors, calibration

DANGER
Do not leave the machine during calibration. The
machine may start to move.

DANGER
The overload system must be function tested after
calibration.
Extreme danger
Deficient calibration may cause load calculation to be
incorrect. The machine must not be operated without
the overload system having been function tested.

NOTE
It is very important for accuracy that all steps are performed in
the given order.

1 Warm up the hydraulic oil to operating temperature, min. 40 °C.

Use lift and extension during warming up in order to heat the oil in
the cylinders.
2 Park the machine on level ground without load, centre the
attachment and apply the parking brake.

10:23
3 To be able to select the function to calibrate, first navigate to the
CUSTOMER SETTI NGS menu for service and settings with or and confirm with .

0
014981

Workshop Manual DRG 420–450 VDRG01.01GB

8:14 8 Control system – Load sensors

10:23 4 Enter service code with or . Confirm each figure with .

Code is obtained from Cargotec Support.
WRI TE PI N CODE
0
NOTE
The code determines which service menus should be activated.
0 0

015625
0

5 Select 8. CONTROL SYSTEM by scrolling with or and

* SETTI NGS & DI AGNOSTI CS*
confirm with .
8 . CONTROL SYSTEM
015624

6 Select 8.2 Monitoring by scrolling with or and confirm with .

* 8 . CONTROL SYSTEM *

8.1 Controls & I n s t r u me n t s

8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015629

7 Select CALIBRATE by scrolling with or and confirm with .

* 8 . CONTROL SYSTEM *
DIAGNOSE INITIATE CALIBRATE
8.1 Controls & I n s t r u me n t s
8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015628

8 Lower the boom to the lowest position (0°). Press to save this
value.
9 Select CALIBRATE 6 by scrolling with .

VDRG01.01GB Workshop Manual DRG 420–450

8 Control system – Load sensors 8:15

10 Lift the boom to its highest angle. Press to save this value.
11 Select CALIBRATE 7 by scrolling with .

12 Retract the boom completely. Press to save this value.

13 Select CALIBRATE 8 by scrolling with .

14 Extend the boom completely. Press to save this value.

15 Select CALIBRATE 9 by scrolling with .

a. Retract the boom completely.

b. Lower the boom and inch towards the end until 2-4 cm
remains on the lift cylinders.
c. Wait approximately five seconds to stabilise the pressure.
d. Press to save this value.
16 Select CALIBRATE 10 by scrolling with .

a. Extend the boom completely.

b. Wait approximately five seconds to stabilise the pressure.
c. Press to save this value.

NOTE
Negative values indicate switched connectors on the pressure
sensors.
Large variations between right and left indicate errors in the
sensors' signals.

Checking the calibration

17 Select CALIBRATE 11 by scrolling with .

Workshop Manual DRG 420–450 VDRG01.01GB

8:16 8 Control system – Load sensors

18 Operate the machine without a load, stop the machine and check
that Actual load = 00000 ± 500 kg.
Check lifting/lowering boom in different operating ranges, as well
as extension long in and extension long out. The boom must not
reach the end positions during checking.
If the weight is not correct, repeat the calibration.

NOTE
Check when stationary. (Operating generates dynamic forces.)

19 Leave Calibration by scrolling out with .

20 Check that the function of the overload system disengages the
boom movement at high load.
a. Take a load and lift it so that it just lifts from the ground.
b. Run out extension and hold the load as close to the ground
as possible.
c. Check that the overload system disengages the boom
movement.

8.2.11.1 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, description

Sensor, hydraulic pressure lift cylinder measures the pressure in the lift
cylinders and is installed on valve block lift cylinder.

The pressure in the cylinders is measured in order to measure the load

as part of the overload system and to determine when regeneration can
be engaged. If the machine is equipped with the option for scale then
the pressure sensors are also used to measure the load.
1 2
The sensors are supplied with voltage by, and send a voltage signal
proportional to the hydraulic oil pressure to Control unit KFU (D7971).

The signals can be checked with the diagnostic menu, see 8.2
Monitoring 17/XX DIAGNOSE, page 8:55 and 8.2 Monitoring 18/XX
DIAGNOSE, page 8:55.
016931

Valve block lift cylinder

1. Sensor, hydraulic pressure lift cylinder, rod
side, left (B7226-3)
Sensor, hydraulic pressure lift cylinder, rod side,
right (B7226-4)
2. Sensor, hydraulic pressure lift cylinder, piston
side, left (B7226-1)
Sensor, hydraulic pressure lift cylinder, piston
side, right (B7226-2)

VDRG01.01GB Workshop Manual DRG 420–450

9:94 9 Frame, body, cab and accessories – Sliding cab

10:23
Hydraulic sliding cab, calibration
CUSTOMER SETTI NGS

1 Machine in service position.

0

2 Start key in operating position.

0

3 To be able to select the function to calibrate, first navigate to the

014981
0
menu for service and settings with or and confirm with .

10:23 4 Enter the code for calibration with or . Confirm each figure
with .
Code is obtained from Cargotec Support.
0 WRI TE PI N CODE

NOTE
0 0 The code determines which service menus should be activated.
015625

5 Select 9. Frame, Cab & Accessories by scrolling with or

* SETTI NGS & DI AGNOSTI CS*
and confirm with .
9 . Fr a me , c a b & a c c e s s o r i e s
017473

6 Select 9.10 Cab Suspension by scrolling with or and confirm

* FAME CAB & ACCESSORI ES *
with .

9. 1 Co n t r ol s & i ns t r ume n t s
9. 2 Sa f e t y & Eme r g e n c y Eq u i p.
9. 3 Se a t
9. 4 Cl i ma t e Sy s t e m
9. 5 Li g h t i n g Sy s t e m
9. 7 Si g n a l l i n g Sys t e m
9. 8 En t e r t a nme n t & Com.
9. 9 Gl a s s Wi n d o ws & Mi r r o r s
9. 1 0 Ca b s u s p e n s i o n
017474

9. 1 1 Ca b i n t e r i o r

7 Select CALIBRATE by scrolling with or and confirm with .

* FAME CAB & ACCESSORI ES *

DIAGNOSE INITIATE CALIBRATE

9. 1 Co n t r ol s & i ns t r u me n t s
9. 2 Sa f e t y & Eme r g e nc y Eq u i p .
9. 3 Se a t
9. 4 Cl i ma t e Sy s t e m
9. 5 Li g ht i n g Sys t e m
9. 7 Si g na l l i n g Sys t e m
9. 8 En t e r t a nme nt & Co m.
9. 9 Gl a s s , Wi n do ws & Mi r r o r s
9. 1 0 Ca b s u s p e ns i o n
017475

9. 1 1 Ca b i n t e r i o r

VDRG01.01GB Workshop Manual DRG 420–450

9 Frame, body, cab and accessories – Sliding cab 9:95

8 Navigate to the calibration menu 9.10 Cab Suspension, menu 1

with / . See Navigation to a menu, work instruction, page 8:98
for an explanation of navigation.
Row 1 shows the cab's position.
Row 2 shows the saved value for the cab's rear position.
9 Run the cab back to its rearmost position. Press Save to store
this value.
The value in row 1, Cab in rear position, is saved in row 2.

10 Navigate to Calibration menu 9.10 Cab Suspension, menu 2 with

/ .
Row 1 shows the cab's position.
Row 2 shows the saved value for the cab's front position.
11 Run the cab forward to its front position. Press Save to store
this position.
The value in row 1, Cab in front position, is saved in row 2.
12 Leave Calibration by scrolling out with .

9.10.4.1 Cab substructure

Cab substructure, description

See Cab substructure, description, page 9:89.

9.10.4.2 Hydraulic oil pump

Hydraulic oil pump, description

Hydraulic sliding cab is supplied with pressure from hydraulic oil pump
3, see Axial piston pump with variable displacement, description, page
10:10.

Workshop Manual DRG 420–450 VDRG01.01GB