GB

Publ. No. 923 862-0006 00-12

Technical Handbook
ECS SERVICE
DCD40-500
ECD40-90L
 0006
DCD40-500/ECD40-90L 00-12
ECS SERVICE Contents Grupp 20 S. 1

Contents

ECS ......................................................................................... 2
Overview ............................................................................ 2
Terminal ............................................................................. 3
Terminal functions .......................................................... 3
Menu structure ............................................................... 4
Operating menus ............................................................ 5
Error messages ............................................................. 6
Service menus ................................................................ 9
Data kits ........................................................................ 12
Different ECU combinations ......................................... 13
ECU 1
SETUP ............................................................................. 14
Setting default values ................................................... 14
01 Automatic gear changing ............................................. 15
Initiation of module 01 .................................................. 15
Throttle settings ........................................................... 16
Calibration .................................................................... 17
04 Lever steering ............................................................... 18
Initiation of module 04
(Trucks supplied before 98-05-18) ................................ 18
Initiation of module 04
(Trucks supplied after 98-05-18) .................................. 20
Parameter adjustment.............................................. 22
Calibration .................................................................... 23
06 Micro steering .............................................................. 24
Initiation of module 06
(Trucks supplied before 98-05-18) ................................ 24
Initiation of module 06
(Trucks supplied after 98-05-18) .................................. 25
Parameter adjustment.............................................. 26
ECU 4
08 El-Servo ....................................................................... 27
ECU 4 SETUP and initiation of module 08 ................... 27
Calibration .................................................................... 30
Diagnostics for module 08............................................. 31
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Overview Group 20 P. 2

Overview
KALMAR ECS - Electronic Control System - is a modular control
and monitoring system to ensure optimum operational security
and total economy. It is possible to combine the system’s different
modules in a number of different way s .
All vital points of the trucks different systems are connected to a
central computer unit, ECU. A terminal display in the operator’s
cab shows current values and generates an alarm if the values
exceed the programmed tolerances.
Either one or two ECUs are fitted, depending on how the machine
in question is equipped.
! ECU 1 is used for different additional modules, such as 01
Automatic Gear Changing, 04 Lever Steering, 06 Micro-
steering, 07 Monitoring.
See separate descriptions in respective sections.
! ECU 4 is used for the control of the 08 module for El-Servo,
10 Empty container attachment, 11 Gantry and
12 Balance.

The ECS

Module Function DCD ECD

01 Provides torque controlled automatic X -
gear changing
04 Provides electro-hydraulic lever X X
steering with or without wheel return
06 Provides electro-hydraulic steering X X
with the micro-steering
07 Monitors the components in the X -
system, e.g., sensors, to ensure their
correct function
Monitors the engine and gearbox to X -
ensure reasonable operating
conditions
08 Provides electro-hydraulic servo X X
steering of the working hydraulics
10 Provides electro-hydraulic servo X -
steering of the empty container
attachment
11 Provides electro-hydraulic servo X -
steering of the Gantry attachment
12 Provides a continuous read-out of X X
the weight of the load

If a fault occurs
– a red warning lamp blinks on the terminal
– an error message appears on the terminal display
– The ECS limits the functions of the truck in different ways
depending on the seriousness of the fault. Certain func-
tions are monitored on two levels, where level 2 limits the
functions of the truck. See the error messages on the ter-
minal display on the following pages.
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 3

Terminal functions
1. Arrow left is used to scroll between the different menus.
8 7
2. Arrow right is used to scroll between the different menus.
3. R is used to reset the display after an error message. All er-
rors, with the exception of certain level 2 errors can be reset
by pressing this button. The red warning lamp is then extin-
guished. The lamp begins to blink again after 3-10 minutes,
depending on the fault, if it has not been rectified.
F
4. - is used to decrease a value.
5. + is used to increase a value.
3 2

KL580B 6. ENTER is used to access the service menus and to save

1 2 3
R new values when setting up and calibrating the system.
4 5
Access to the service menus also requires the use of special
codes, that are separately obtainable from KALMAR.
7. A red warning light blinks in the event of an error and is ex-
tinguished when reset by pressing button 3.
R 8. The terminal display has 4 lines with space for 20 characters
1 2 3 on each line.

4 5

6
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 4

Menu structure
There are three types of menu
1. Operating menus
The operating menus are accessible to the operator. The
menus that can be selected depend on how the truck is
equipped and are determined in SETUP. All operating menus
are part of a connected loop. Use arrow RIGHT/LEFT to
move around the loop. The loop also contains
2. Error messages
Displayed automatically and have priority over other menus.
3. Service menus
The operating menu loop always contains the KALMAR
INDUSTRIES SERVICE main menu.The service sub-menus
under this main menu require access to codes that can be
found on a special list from KALMAR. If ENTER is pressed
by mistake in the service menu and the ENTER CODE menu
is displayed, return to the operating menu by pressing EN-
TER.
For further information, refer to the respective headings.

1.
1. G E A R B O X
1.
E N G I N E
O I L T EM P 9 8 C
O I L P R E S S U R E 1 8 . 5 B A R H Y D F L U I D T EM P 8 9 C
C O O L A N T T EM P 9 8 C
B A T T E R Y L E V E L 2 4 V
O I L P R E S S U R E 4 . 5 B A R
1.
S E R V I C E 3 4 5 : 2 3 : 0 8
I N T E R V A L
T I M E T O N E XT
S E R V I C E 1 5 8H

F 2 1 6 2 0 R P M
2 2 K P H
E F K A L M AR I N D U S T R I E S
F U E L S E R V I C E

E N T E R

3. Enter
2.
0 1 B A T T E R Y L E V E L
E X T R E M E L Y L OW E N T E R C OD E
R E D U C E D R P M
S E R V I C E !

KL.828GB

3. Service menues
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DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 5

Operating menus
F2 = Current gear The menus that are displayed on the terminal depend on the
F = Forward modules with which the truck’s ECS is equipped. The overview
N = Neutral below shows the possible combinations. Use either arrow
R = Reverse RIGHT/LEFT to switch between menus. All operating menus are
1620 RPM = current engine revs in a connected loop.
22 KM/H = Speed of truck Access to the sub-menus under the service menu requires an ac-
FUEL E = Tank empty cess code. If ENTER CODE is displayed by mistake, return to the
FUEL F = Tank full
operating menu by pressing ENTER.

01 Automatic gear changing N.B. Additional menus may occur as a result of adaptation to
07 Monitoring specific customer requirements.
08 El-Servo
12 Balance

08

K A L M AR I N D U S T R I E S
S E R V I C E
12 E N T E R

WE I G HT # # # . # T

+/ - / R /E NT E R

01.08

F 2 1 6 2 0 R P M
2 2 K P H

K A L M AR I N D U S T R I E S
S E R V I C E

12 E N T E R

WE I G HT # # # . # T

+/ - / R /E NT E R

K A L M AR I N D U S T R I E S

07.08 S E R V I C E S
I
E
N
R
T
V I C E
E R V A L
3 4 5 : 2 3 : 0 8

01.07.08 E N T E R T
S
I
E
M
R
E T O
V I C E
N E X T
1 5 8 H

H Y D F L U I D T EM P 8 9 C
F 2 1 6 2 0 R P M B A T T E R Y L E V E L 2 4 V
2 2 K P H
E F
F U E L
E N G I N E G E A R B O X

C O O L A N T T EM P 9 8 C O I L T EM P 9 8 C
12 O I L P R E S S U R E 4 . 5 B A R O I L P R E S S U R E 1 8 . 5 B A R

WE I G HT # # # . # T

+/ - / R /E NT E R KL829GB

Operating menus with different module combinations

 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 6

Error messages
In order of priority. If two faults occur at the same time, the termi-
nal displays the fault with the highest priority.
N.B. Error messages always have higher priority than normal menus.
Pressure and temperature Faults 01-08 are level 2 faults and cannot be reset before the fault
limits may vary depending on is rectified.
the choice of transmission The first two figures show to which module the error message re-
and engine data kits. lates. (These figures are not shown on the display)
01 = Automatic gear changing
04 = Lever steering
06 = Mini-steering
07 = Monitoring
08 = El-Servo
07 01 BATTERY VOLTAGE
VERY LOW/HIGH 1. The voltage is outside 14,0 - 29,7V for 7 sec.
RPM REDUCTION
SERVICE!
01 02 ACCELERATOR NOT
07 FUNCTIONING 2. The voltage is outside 0,5 - 9,5V for 7 sec.
RPM REDUCTION
SERVICE!

01 03 INJECTOR PUMP
07 MOTOR NOT FUNC 3. The voltage is outside 0,5 - 9,5V for 7 sec.
RPM REDUCTION
SERVICE!

01 04 GEAR LEVER NOT 4.

07 FUNCTIONING
RPM REDUCTION
SERVICE!

07 05 ENGINE OIL PRESS 5. The engine oil pressure is lower than 0.7 bar for 20 sec (Volvo)
EXTREMLY LOW ##.#bar
RPM REDUCTION
SERVICE!

07 06 COOLANT TEMP 6. The coolant temperature is higher than 103°C i 20 sec.

EXTREMELY HIGH ###°C
RPM REDUCTION
SERVICE!
07 07 GEARBOX OIL PRES 7. The oil pressure is lower than 12.0 bar for 20 sec (Volvo).
EXTREM LOW ##.#bar
RPM REDUCTION
SERVICE!

07 08 GEARBOX OIL TEMP 8. The oil temperature is higher than 116°C for 30 sec (Volvo).
EXTREMELY HIGH ###°C
RPM REDUCTION
SERVICE!

01 09 ENGINE REV 9. The engine rev is <400 r/min and the speed >3,0 km/h for 3
07 SENSOR FAULT
sec.
RPM REDUCTION
SERVICE!

07 10 LOW ENGINE OIL 10.The engine oil pressure is lower than 1.0 bar for 20 sec
PRESSURE ##.#bar (Volvo).
CHECK OIL LEVEL

07 11 HIGH COOLANT 11.The coolant temperature is higher than 98°C for 20 sec.
TEMPERATURE ###°C
CHECK COOLANT LEVEL

07 12 LOW GEARBOX OIL 12.The gearbox oil pressure is lower than 14 bar for 20 sec
PRESSURE ##.#bar (Volvo).
CHECK OIL LEVEL
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 7

07 13 HIGH GEARBOX 13.The gearbox oil temperature is higher than 113°C for 30 sec.
TEMPERATURE ###°C (Volvo)
CHECK OIL LEVEL

07 14 FUEL EXTREMELY 14.Fuel content in the tank <15% for 40 sec.

LOW FILL TANK
TO AVOID AIR
IN THE SYSTEM
07 15 LOW COOLANT 15.The in signal on ECU 1 pin 33 is >12V for 40 sec.
LEVEL
TOP UP
COOLANT FLUID

07 16 HIGH HYDRAULIC 16.The hydraulic oil temperature is higher than 100°C for 40 sec.
FLUID TEMPERATURE
OPERATION POSSIBLE
SERVICE!

07 17 SENSOR FAULT 17.The sensor resistance is >193 ohm for 4 sec.

FUEL GAUGE
OPERATION POSSIBLE
SERVICE!

07 18 SENSOR FAULT 18..The gearbox oil pressure sensor is faulty.

GEARBOX OIL PRESSURE
OPERATION POSSIBLE
SERVICE!

07 19 SENSOR FAULT 19.The engine oil pressure sensor is faulty.

ENGINE OIL PRESSURE
OPERATION POSSIBLE
SERVICE!

07 20 SENSOR FAULT 20.The coolant temperature sensor indicates >128°C

COOLANT TEMP
OPERATION POSSIBLE
SERVICE!

07 21 SENSOR FAULT 21.The gearbox oil temperature sensor indicates >138°C.

GEARBOX OIL TEMP
OPERATION POSSIBLE Faulty sensor.
SERVICE!

07 22 SENSOR FAULT 22.The hydraulic oil temperature sensor indicates 138°C

HYDRAULIC FLUID TEMP
OPERATION POSSIBLE Faulty sensor.
SERVICE!

07 23 SERVICE INTERVAL 23.

EXCEEDED
SERVICE TRUCK
SOONEST!

01 24 SPEED SENSOR 24.The speed sensor indicates a speed change >3 km/h for
07 FAULT approx. 0,1 sec.
RPM REDUCTION
SERVICE! Faulty sensor.

04 25 STEERING LEVER 25.The out signal from the steering lever is not within 0,4 - 9,6V.
FAULT SWITCH OFF THE Faulty steering lever.
STEERING SYSTEM
SERVICE!

04 26 STEER SENSOR FAULT 26.The out signal from the steering angle sensors not within
SWITCH OFF THE 0,4 - 9,6V.
STEERING SYSTEM
SERVICE! Faulty steering angle sensor.
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 8

06 27 MINI STEERING 27.The out signal from the mini steering wheel is not within
FAULT SWITCH OFF 0,4 - 9,6V
THE STEERINGSYST Faulty mini steering wheel.
SERVICE!
07 28 WARNING!
LOW BRAKE PRESSURE 28.The in signal on ECU 4 pin 55 is >12V and the engine speed
SERVICE! is >400 r/minfor i 10 sec.

08 45 LEVER F1
FAULTY INPUT SIGNAL 45. The in signal on ECU 4 pin 42 is not within 0,1 - 9,9V.

08 46 LEVER F2
FAULTY INPUT SIGNAL 46. The in signal on ECU 4 pin 66 is not within 0,1 - 9,9V.

08 47 LEVER F3
FAULTY INPUT SIGNAL
47. The in signal on ECU 4 pin 67 is not within 0,1 - 9,9V.

08 48 LEVER F4 48. The in signal on ECU 4 pin 52 is not within 0,1 - 9,9V.
FUALTY INPUT SIGNAL

08 49 LEVER F5 49. The in signal on ECU 4 pin 40 is not within 0,1 - 9,9V.
FAULTY INPUT SIGNAL
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 9

Service menus
All service sub-menus are accessible from the main KALMAR
INDUSTRIES SERVICE menu, thereafter, a code must be regis-
tered. There are two different codes, codes 1 and 4.
! Code 1 leads to the SETUP, INITIATION and CALIBRATION
of the modules in ECU1.
! Code 4 leads to the INITIATION and CALIBRATION of the el-
servo module in ECU 4.
Definition of terms:
SETUP is the setting of the basic values of the machine, defining,
for example, the modules with which the machine is equipped.
This determines which operational menus then appear.
INITIATION is the basic setting of the different modules’ parame-
ters.
CALIBRATION is the individual adjustment of the max. and min.
values of the different modules’ signals. Calibration is unique for
each machine.
The illustrations below and on the following page provide an over-
view of all available service menus. All of them are accessed from
the KALMAR INDUSTRIES SERVICE main menu.

K A L M AR I N D U S T R I E S
S E R V I C E

( E N T E R )

E N T E R C O D E

Code 1
R E T U R N T O M A I N M E N U C A L I B R A T I O N
S T E E R I N G L E V E R A N D
W HE E L P O S I T I ON
E N T E R E N T E R
S E T U P I N I T I A T I O N M O DU L E 0 4
L E V E R S T E E R I NG

E N T E R EN T E R

S E R V I C E I N T E R V A L C A L I B R A T I ON
2 0 0 ( + / - ) I N J E C T I ON MO T O R AN D
T I ME T O N E X T S E R V I C E I N I T I A T I O N MO D U L E 0 1 A C C E L E R A T O R P E D AL
E N T E R A U T OM A T I C G E A R E NT E R
C H A N G E
E N T E R

1 2 14 1 2 3
13
5 4
12 INITIATION
SETUP ECU1 3
MODULE 04 5
11 6
4 10 9 8 7

12 1 2 7 1 2
11 3
INITIATION CALIBRATION
10 4 6 3
MODULE 01 MODULE 01
9 5
8 7 6 5 4

7 1 2
CALIBRATION
6 MODULE 04 3

KL722GB 5 4
Service menus under
Code 1, modules 01-04-07
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 10

K A L M AR I N D U S T R I E S
S E R V I C E

( E N T E R )

E N T E R C OD E

Code 1
R E T U R N T O M A I N ME N U

S E T U P E N T E R
I N I T I AT I O N MO D U L E 0 6
M I C R O S T E E R I N G

E N T E R E N T E R

S E R V I C E I N T E R V A L C A L I B R A T I ON
2 0 0 ( + / - ) I N J E C T I ON M OT O R A N D
T I ME TO N E X T SE R V I C E I N I T I A T I ON MO D U L E 0 1 A C C E L E R AT OR P E DA L
E N T E R A U T OM A I C G E A R E NT E R
C H A N GE
E N T E R

1 2 1
8 2
5 INITIATION
SETUP ECU1 3 7 3
MODULE 06
6 4
4 5

12 1 2 7 1 2
11 3
INITIATION CALIBRATION
10 4 6 3
MODULE 01 MODULE 01
9 5
8 7 6 5 4 KL722AGB

Service menus under

Code 1, modules 01-06-07
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Terminal Group 20 P. 11

K A L M A R I N D U S T R I E S
S E R V I C E

( E N T E R )

E N T E R C O D E

Code 4 Code 5
R E T U R N T O MA I N M E N U

E N T E R
S E T U P / I N I T MO D U L E 0 8 C A L I B R A T I ON
E L - S E R V O E L - S E R V O

E N T E R E N T E R

19 20 21 1 2 3 8 1 2
18 4
ECD 5
17
6 7 CALIBRATION 3
16 SETUP/INITIATION
MODULE 08 7 MODULE 08
15
14 9 8 6 4
13 12 11 10 5 KL723E-GB

11 1 2
10 3

DIAGNOSTICS 4
9
8 5
7 6

Detailed information about the different service menu paths can

be found under respective section descriptions.
The connected loops then appear as shown to the left.
The arrows beside the menus show the switch paths between
menus. Use arrow RIGHT/LEFT buttons.

Service menus under

Code 4 and 5, module 08
 0006
DCD40-500/ECD40-90L ECS 00-12
ECS SERVICE Data kits Group 20 P. 12

Data kit transmissio n

Data kit Truck Gearbox No. of Ratio Wheel Wheel
nr gears dimensions radius
3 DCD90-160 13.7HR-28334 3 1:14.4 11.00x20 0.51
4 DCD90-160 13.7HR-32335 3 1:14.4 12.00x20 0.53
13.00x22.5
5 DCD90-160 13.7HR-28334 3 1:14.4 12.00x20 0.53
6 DCD40-90 12.6HR-18213 2 1:14.0 8.25x15 0.407
7 DCD40-90 BW PR2 2 1:14.0 315/70x15 0.400
11 DCD200-320 32312 3 1:27.51 16.00x25 0.68
12 EC2-8 - 1 1:24 8.25x15 0.407
15 DCD100XL 12.6HR-18302 3 1:14.4 12.00x20 0.53
17 DCD90-160 13.7HR-28334 3 1:14.4 9.00x20 0.493
18 DCD90-160 13.7HR-28334 3 1:14.4 10.00x20 0.498
20 EC5.5-600 - 1 1:51.4 355/65x15 0.42 *
21 ECD55-600 - 1 1:23.6 355/65x15 0.42 *
22 EC3-500 - 1 1:23.6 12.5x15 0.345
23 DCB25E7 13.7HR-32335 4 1:14.4 12.00x20 0.585
24 DCD40-90 12.6HR-18213 2 1:14.4 355/65x15 0.42
25 DCD120-6 12.6HR-18302 3 1:14.4 10.00x20 0.498
26 DCD280-320 15.5HR-32312 3 1:32.07 16.00x25 0.68
27 DCD320 15.5HR-36432 4 1:31.71 16.00x25 0.68
28 DCD320-450 15.5HR-36432 4 1:31.71 18.00x25 0.73
29 DCD40-90 BW PR2 2 1:14.0 8.25x15 0.407
355x65x15 0.42
32 DCD90-160 13.7HR-28334 3 1:14.4 11.00x20 0.51
33 DCD90-160 13.7HR-32335 3 1:14.4 12.00x20 0.53
13.00x22.5 0.52
34 DCD90-160 13.7HR-28334 3 1:14.4 12.00x20 0.53
35 DCD100XL 12.6HR-18302 3 1:14.4 12.00x20 0.53
36 DCD90-160 13.7HR-28334 3 1:14.4 9.00x20 0.493
37 DCD90-160 13.7HR-28334 3 1:14.4 10.00x20 0.498
38 DCD120-6 12.6HR-18302 3 1:14.4 10.00x20 0.498
* Massiva hjul

Data kit engine

Data kit Truck Engine Model Pulses per Max. Comments
n:o engine rev. r.p.m.
1 DCD VOLVO TD 630 30 2500
90-160
7 DCD VOLVO TWD 731 30 2350
90-250
9 DCD Perkins 1006-6T 2 2400 External sensor, crankshaft pulley
90-160
10 DCD Perkins 1006-6T 2 2650 External sensor, crankshaft pulley
90-160
11 DCD Perkins 1006-6T 126 2400 Magnetic pickup
90-160
12 DCD Perkins 1006-6 126 2650 Magnetic pickup
90-160
13 DCD 320 - VOLVO TWD 1031 30 2250
TWD 1231
 0006
DCD40-500/ECD40-90L ECU 00-12
ECS SERVICE Combinations Group 20 P. 13

Different ECU combinations

On each ECU there are four DIP switches.

Ensure that the DIP switches are set in the positions shown in the
adjacent illustrations.
ECU 4

1 2 34
ON ECU 4 = Module 08 El-Servo
OFF ECU 4 DIP switches 1-2-3-4 in the ON position

ECU 1 = Module 01 Automatic gear changing

Module 04 Lever steering/Module 06 Micro-steering
Module 07 Monitoring
ECU 1 DIP switches 1-2-3-4 in the ON position
ECU 1
1 2 34
When ECU1 and ECU4 are combined, ECU 1 becomes subser-
ON
vient (a slave to) to ECU 4.
OFF ECU 1 DIP switches 1-2-3 in ON position 4 in OFF position
ECU 4 DIP switches 1-2-3-4 in the ON position

Other positions for the ECU 1 DIP switches

! DIP switch 1 ON for trucks where the prop shaft revolutions
sensor gives 2 pulses per revolution
! DIP switch 1 OFF for trucks where the prop shaft revolutions
sensor gives 16 pulses per revolution
ECU 1 ECU 4
! DIP switch 2 ON with fixed and rotatable operator seats. With
rotatable operator seats the signals switch over between
pins 11 and 31 in to ECU 1
! DIP switch 2 OFF with 45° turnable seat. Here the signals
shall not switch over between pins 11 and 31.
! DIP switch 3 must always be in the ON position in this appli-
cation.
KL831

1 2 34 1 2 34 Setting of gearbox disengagement

ON ON (Trucks supplied before week 945)
OFF OFF
! Disengagement, independent of engine speed:
ECU 1, DIP switch 3 ON.
After releasing the clutch pedal, the set gear is activated in-
dependent of engine speed.
! Disengagement, depending on engine speed:
ECU 1, DIP switch 3 OFF.
DIP switches After releasing the clutch pedal, the engine speed must be
1 2 3 4 reduced below set level before any gear can be activated.
The engine speed level is set according to ECU 1 SETUP,
ON Menu 1
OFF Setting of gearbox disengagement
(Trucks supplied after week 945)
KL831A The function of DIP switch 3 is moved to ECU 1 SETUP, Menu 1.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE SETUP Group 20 P. 14

ECU 1 SETUP, setting Nominal values

Study the menu overview under ECS, Terminal.
Switch between sub-menus using the RIGHT/LEFT arrow keys.
Use the +/- buttons to increase or decrease the set values.
KALMAR INDUSTRIES
SERVICE Save the new value by pressing ENTER.
! Switch to the SERVICE menu with arrow RIGHT/LEFT.
ENTER Press ENTER.

! Register code 1. (The code can be found on the list supplied

ENTER CODE X by KALMAR)
Press ENTER.
ENTER=RETURN

SETUP
BASIC SETTING ! Press ENTER.
ECU 1
ENTER

SETUP 1(5) 1. Not used.

(Machines supplied before 1998-05-18.)
1. 0,1,2 affects both engine revs and speed for permissible
gear changing between F/N/R. Recommended value = 1.
SETUP 1(5) (Machines supplied after 1998-05-18.)
XXXX Machines delivered after week 945:
REV INTERLOCK XXXX 0, 1, 2 correspond to the OFF position on switch 3, ECU 1
0=LO 1=MED 2=HI
which should be the standard setting, recommended
value = 1.
SETUP 2(5) 3, 4, 5 correspond to the ON position on switch 3, ECU 1,
XXXX Setting Level Engine revs, rpm Speed, km/h
MODULES ECU1 XXXX 0 Low 900 0.5
1 Medium 1000 3.0
2 High 1100 3.0/6.0 *)
3 Low Independent 0.5
4 Medium Independent 3.0
SETUP 3(5)
XXXX 5 High Independent 3.0/6.0 *)
DATA SET XXXX *) 20-45 tonne machines only 3.0 km/h
TRANSMISSION 2. Register the value for the machines modules on line 3.
Save by pressing ENTER.
The value is the sum of the values for the modules with which
SETUP 4(5)
XXXX the machine is equipped. This figure determines which men-
DATA SET ENGINE XXXX us are shown on the ECS terminal display.
The values for the modules are obtained through KALMAR.
Switch menus with arrow RIGHT.
SETUP 5(5) 3. Register the data kit number (obtained from KALMAR) for
SETUP COMPLETED the transmission in question on line 3.
Save by pressing ENTER. Switch menus with arrow RIGHT.
ENTER
4. Register the data kit number (obtained from KALMAR) for
the engine in question on line 3.
Save by pressing ENTER. Switch menus with arrow RIGHT.
SETUP 5. SETUP is now completed. Press ENTER.
BASIC SETTING
ECU 1
ENTER ! Press arrow RIGHT to move on to the SERVICE INTERVAL
menu.

SERVICE INTERVAL
XXXX0 (+/-) ! If the service interval is to be altered, use the + / - buttons on
TIME TO NEXT SERVICE the terminal.
XXXXX H ENTER
If the service interval is to be reset and a new service interval
started, press ENTER.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 01 Automatic gear changing Group 20 P. 15

INITIALIZE MODULE 01
AUTOMATIC GEARCHANGE
AND ELEC ACCELERATOR
ENTER
Initiation of module 0 1
Study the menu overview under ECS, Terminal.
Switch between sub-menus using the RIGHT/LEFT arrow keys.
Use the +/- buttons to increase or decrease the set values.
Save the new value by pressing ENTER.
! Switch to the INITIATION menu with arrow RIGHT/LEFT.
Press ENTER.

INIT 01 1(12) 1. Nominal value 30-40. Determines the timing of changing

XX.XX down through the gears. Higher value = earlier change
SLIP FACTOR XX.XX down. Lower value = later change down, i.e., the gearbox re-
4>3 AND 3>2 mains in the higher gear longer.
2. Nominal value 80-85. Determines the timing of changing up
INIT 01 2(12) through the gears. Lower value = earlier change up.
XX.XX
SLIP FACTOR XX.XX Higher value = later change up, i.e., allows higher engine rev-
2>3 AND 3>4 olutions per gear.
3. Nominal value 70-85. Determines the timing of changing up
INIT 01 3(12) from 1st to 2nd. Lower value = earlier change up.
XX.XX
SLIP FACTOR XX.XX Higher value = later change up, i.e.,allows higher engine rev-
1>2 olutions in 1st gear.
4. Nominal value 0-25. Determines the amount of power re-
INIT 01 4(12) quired by the injection pump motor to return the throttle arm
XXXX on the injection pump. The injection pump operates in paral-
MAX POWER TO XXXX
REDUCE GAS lel with the power of the return spring. (Menus 4-7 determine
throttle characteristics, see next page Throttle Settings)
5. Nominal value 0-25. Determines how much power needs to
INIT 01 5(12) be applied to the injection pump motor when a small in-
XXXX crease in engine revolutions is required. When the accelera-
POWER TO XXXX
INCREASE GAS tor is depressed a little, engine revolutions should increase a
little. This entails counteracting the power of the return
spring. If this is not the case, alter the value.
INIT 01 6(12)
XXXX 6. Nominal value 100-160. Determines how quickly engine
MAX POWER XXXX revolutions increase when the accelerator is depressed to
TO INCR GAS XXXXrpm the floor, i.e., the speed of the throttle arm.
7. Nominal value 0-25. Determines the maximum power re-
INIT 01 7(12) quired by the injection pump motor to reduce throttle when
XXXX the accelerator is released.
IDLING GAS XXXX
POWER

8. Nominal value 0-5. Determines how long engine revolutions

INIT 01 8(12) are reduced when changing up from 2000 RPM.
XXXX
GEARCHANGE TIME XXXX
AT 2000rpm
9. Nominal value 0-10. Determines how long engine revolu-
INIT 01 9(12) tions are reduced when changing up from 1400 RPM.
XXXX N.B. Menu 9 must have the same or higher value than menu
GEARCHANGE TIME XXXX 8.
AT 1400rpm

INIT 01 10(12) 10. The defined value limits the speed of the machine, in kph.
XXXX
SPEED LIMIT XXXX
0=NO LIMIT
11. 0 = normal gear changing
INIT 01 11(12) 1 = start in 2nd. Only when gear lever is in position 4.
XXXX
START IN 2ND XXXX If the gear lever is in position 3, this function does not apply.
GEAR 1=2ND

Continued
on next page
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 01 Automatic gear changing Group 20 P. 16

INIT 01 12(12)
INITIATION MODULE 01
COMPLETED 12. Initiation of module 01 is now completed. Press ENTER
ENTER

INITIALIZE MODULE 01 ! Switch to the CALIBRATION menu using the RIGHT/LEFT

AUTOMATIC GEARCHANGE arrow keys.
AND ELEC ACCELERATOR ! Alternatively. Press the RIGHT/LEFT arrow keys to access
ENTER
the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.

Throttle settings
The throttle may need to be reset after a certain period of opera-
tion, once all parts of the throttle mechanism have worn them-
selves in.

1. Switch to menu 5 under INITIATION.

2. An increased throttle value gives a response to quick, light
pressure on the accelerator.

3. Switch to menu 6. Depress the accelerator half way - quickly.

INIT 01 4(12) Set the value in menu 6 so high that the throttle over-runs
XXXX
MAX POWER TO XXXX slightly, i.e., engine revolutions continue to increase slightly
REDUCE GAS when the accelerator is stationary. Repeat the process sev-
eral times, reducing the value until the over-run disappears.

INIT 01 5(12) 4. Still in menu 6, kick-down from 0 throttle to max throttle and
XXXX
POWER TO XXXX check that the engine revs to a maximum of 2300 rpm.
INCREASE GAS Note: The values in menus 5 and 6 may be such that you
must choose between a slight over-run or a slight reduction
of maximum revs.
INIT 01 6(12)
XXXX
MAX POWER XXXX 5. Switch to menu 4. Reduce the value as much as is possible.
TO INCR GAS XXXXrpm Depress and release the accelerator and check that the cor-
responding increase and decrease in throttle occurs.
INIT 01 7(12)
XXXX 6. Switch to menu 7. Reduce the value so that even when the
IDLING GAS XXXX
POWER accelerator is released very slowly to 0, the engine revs de-
crease to idling speed. If, for example, revs stop at 800 rpm
the menu value is too low. Increase it and check again.

7. If throttle characteristics are not correct after the above

measures, carry out CALIBRATION.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 01 Automatic gear changing Group 20 P. 17

Calibration
Study the menu overview under ECS, Terminal.
Switch between sub-menus using the RIGHT/LEFT arrow keys.
Use the +/- buttons to increase or decrease the set values.
Save the new value by pressing ENTER.
When a new accelerator pedal or injection pump motor is in-
stalled, minimum and maximum values must be calibrated. The
CALIBR OF MODULE 01 engine should be switched off, but the ignition ON.
INJECTOR PUMP MOTOR
AND ACCELERATOR Note. If, for example, only the accelerator is to be calibrated, do
ENTER not skip the menu using arrow RIGHT/LEFT.
! Switch to the CALIBRATION menu with arrow RIGHT/LEFT.
Tryck ENTER.
CALIBR 01 1(7) 1. The system will now give maximum throttle.
INJECTOR PUMP XXXX Check the injection pump to ensure that the injection pump
MOTOR MAX XXXX motor has set the throttle in the max. position.
VALUE XXXXrpm Watch the display and wait until it has stabilized at a maxi-
mum value.
Press ENTER to save this value as “max. throttle”.
Press arrow RIGHT to move on.
CALIBR 01 2(7)
INJECTOR PUMP XXXX 2. As before, wait until the display has stabilized at a minimum
MOTOR MIN XXXX value.
VALUE XXXXrpm Note that the value for max. throttle must be greater than the
value for min. throttle.
Press ENTER to save this value as “min. throttle”.
CALIBR 3(7) Press arrow RIGHT to move on.
PRESS ACCELR XXXX
PEDAL 1 XXXX 3. Press the accelerator to the floor and wait a few seconds.
TO THE FLOOR Press ENTER to save the value as the maximum position of
the accelerator pedal. Press arrow RIGHT to move on.

CALIBR 4(7) 4. Release the accelerator pedal and wait a few seconds.
RELEASE XXXX Press ENTER to save this value as the minimum position of
ACCELERATOR XXXX
PEDAL 1 the accelerator pedal. Press arrow RIGHT to move on.

CALIBR 5(7) 5. Option.

PRESS ACCELR XXXX Repeat point 4 for accelerator pedal 2.
PEDAL 2 XXXX
TO THE FLOOR

CALIBR 6(7)
RELEASE XXXX 6. Option.
ACCELERATOR XXXX Repeat point 5 for accelerator pedal 2.
PEDAL 2

CALIBR 01 7(7)
CALIBRATION OF
INJECTION PUMP MOTOR 7. Press ENTER to conclude calibration.
ACCELERATOR OK ENTER

CALIBR OF MODULE 01 ! Move on using the RIGHT/LEFT arrow keys.

INJECTOR PUMP MOTOR
AND ACCELERATOR ! Alternatively. Press the RIGHT/LEFT arrow keys to access
ENTER the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 04 Lever steering Group 20 P. 18

Initiation of module 0 4
(Trucks supplied before 98-05-18 )
Study the menu overview under ECS, Terminal.
INITIATION MODULE 04 Switch between sub-menus using the RIGHT/LEFT arrow keys.
LEVER STEERING Use the +/- buttons to increase or decrease the set values.
Save the new value by pressing ENTER.
ENTER
! Switch to the INITIATION menu with arrow RIGHT/LEFT.
Press ENTER.

INIT 04 1(14) 1. Nominal value 10. Determines how much lever movement
NEW VALUE XX
DEAD ZONE LEVER XX around the neutral position the system will interpret as neu-
tral.
2. Select wheel return or non-return system.
INIT 04 2(14) 0 = Wheel return system.
NEW VALUE XX 1 = Non-return system.
WHEEL RETURN XX

INIT 04 3(14) 3. Nominal value 50. Setting of break point 1 (BP 1). Affects
NEW VALUE XX the characteristics of the steering, see see Technical Hand-
BREAK POINT 1 XX book ECS DCD 90-450, Lever steering characteristics sec-
tion under 04 Lever steering (applies to points 3-7).
INIT 04 4(14)
NEW VALUE XXX 4. Nominal value 100. Setting of break point 2 (BP 2).
BREAK POINT 2 XXX

INIT 04 5(14)
NEW VALUE XX 5. Nominal value 150. Setting of break point 3 (BP 3).
BREAK POINT 3 XX

INIT 014 6(14)

NEW VALUE XX 6. Nominal value 65. Percentage of max. steering capability at
PERCENT AT bp 2 XX
BP 2.

INIT 04 7(14)
NEW VALUE XX 7. Nominal value 40. Percentage of max. steering capability at
PERCENT AT BP 3 XX BP 3. (Only applies to wheel return systems).

INIT 04 8(14)
NEW VALUE XX 8. Nominal value 85. Degree of fine steering for the steering
FINE STEERING XX lever. (Only applies to wheel return systems).
STEERING LEVER

INIT 04 9(14) 9. Nominal value 1. Determines the acceptable wheel angle

NEW VALUE XX
DEAD ZONE XX when steering begins. Not normally altered.
WHEEL ANGLE (Only applies to wheel return systems).

INIT 04 10(14)
NEW VALUE XX
FAULT MAX CURRENT XX 10. Not normally altered.
INCREASE (Only applies to wheel return systems)

INIT 04 11(14)
NEW VALUE XX 11. Not normally altered.
FAULT MAX CURRENT XX (Only applies to wheel return systems)
DECREASE

Continued
on next page
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 04 Lever steering Group 20 P. 19

INIT 04 12(14)
12. Nominal value 80. If min.current increases, the valve starts
NEW VALUE XX to open, i.e., the wheels begin to move. Min. current should
MIN CURRENT TO XX be set so that the wheels are still when the truck stands still
STEERING VALVE with the engine running.

INIT 04 13(14)
NEW VALUE XX
MAX CURRENT TO XX 13. Nominal value 165. Maximum current out to the steering
STEERING VALVE valve. Adjust when valve is replaced.

INIT 04 14(14)
INITIATION MODULE 04 14. Initiation module 04 completed.
COMPLETED
ENTER Press ENTER to return to the Initiation start menu.

INITIATION MODULE 04 ! Switch to the CALIBRATION menu using the RIGHT/LEFT

LEVER STEERING
arrow keys.
ENTER ! Alternatively. Press the RIGHT/LEFT arrow keys to access
the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 04 Lever steering Group 20 P. 20

Initiation module 04
INITIALIZE MODULE 04 (Trucks supplied after 98-05-18)
STEERING
Study the menu overviews under ECS, Terminal.
ENTER Scroll through the sub-menus with arrow RIGHT/LEFT. Increase/
decrease set values with +/-. Save new values with ENTER.
! Switch to the INITIATION menu with arrow RIGHT. Press
INIT 04 1(14) ENTER.
XXXX 1. Nominal value 0.
CHARACTER LEVERXXXX Register the sensitivity of the steering lever.
0-31, 0=LIN
0 = wheel displacement in direct relationship to lever move-
INIT 04 2(14) ment through the whole range of lever movement
XXXX 32 = wheel displacement is less at the start of lever move-
TYPE OF STEERINGXXXX ment and greater at the end of the movement
0=NO FEEDBACK

Output signal
0

INIT 04 3(14)
XXX.X 32
BREAK POINT XXX.X
BP1 km/h

INIT 04 4(14)
XXX.X
BREAK POINT XXX.X
BP2 km/h KL1116
Lever movement
2. Nominal value 1.
INIT 04 5(14)
XXX.X Select wheel return or non-return system.
BREAK POINT XXX.X 0 = Wheel return system.
BP3 km/h 1 = Non-return system.
3. Nominal value 5. Setting of break point 1 (BP 1). Affects the
INIT 04 6(14) characteristics of the steering, see Technical Handbook ECS
XXXX DCD 90-450, Lever steering characteristics section under 04
PERCENT AT BP2XXXX Lever steering (applies to points 3-7).
4. Nominal value 10. Setting of break point 2 (BP 2).
5. Nominal value 15. Setting of break point 3 (BP 3).
INIT 04 7(14)
XXXX 6. Nominal value 65. Percentage of max. steering capability at
PERCENT AT BP3XXXX BP 2.
7. Nominal value 40. Percentage of max. steering capability at
BP 3. (Only applies to wheel return systems).
INIT 04 8(14)
XXXX
P-FACTOR XXXX 8. Nominal value 20. P-factor.
(Only applies to wheel return systems)

INIT 04 9(14) 9. Nominal value 1. Determines the acceptable wheel angle

XXXX when steering begins. Not normally altered.
DEAD ZONE XXXX
WHEEL ANGLE (Only applies to wheel return systems).

10. Nominal value 150. Set the start and stop voltage (menus
INIT 04 10(14)
XXXX 10 and 11) to a value, the same value for start and stop, so
START VOLTAGE XXXX that the wheels just begin to move. Then set the start voltage
STEERING RIGHT to one unit less than this value.

INIT 04 11(14) 11. Nominal value 200. Move the steering lever to maximum po-
XXXX sition and set a value for stop voltage. The higher the value,
END VOLTAGE XXXX
STEERING RIGHT the faster the wheel displacement. Adjust the value for the
stop voltage so that the required steering characteristics are
achieved.

Continued on next page

 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 04 Lever steering Group 20 P. 21

INIT 04 12(14) 12. Nominal value 150. Same setting as menu 10 but for left
XXXX
START VOLTAGE XXXX movement.
STEERING LEFT

INIT 04 13(14)
XXXX 13. Nominal value 200. Same setting as menu 11 but for left
END VOLTAGE XXXX
STEERING LEFT movement.

INIT 04 14(14)
INITIATION MODULE 04 14. Initiation module 04 completed.
COMPLETED
ENTER Press ENTER to return to the Initiation start menu.

INITIALIZE MODULE 04 ! Switch to the CALIBRATION menu using the RIGHT/LEFT

STEERING arrow keys.
! Alternatively. Press the RIGHT/LEFT arrow keys to access
ENTER
the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 04 Lever steering Group 20 P. 22

Parameter adjustment
1. Set DEAD ZONE WHEEL ANGLE (INIT 04 9) to 0.
2. Set P factor (INIT 04 8) to 30. This means that regulation er-
rors greater than 30% of the maximum steering angle will be
regulated with maximum START VOLTAGE STEERING
RIGHT & LEFT (INIT 04 10/INIT 04 12) and END VOLTAGE
STEERING RIGHT & LEFT (INIT 04 11/INIT 04 13). See
illustration.
3. Set the START VOLTAGE STEERING RIGHT (INIT 04 10)
and END VOLTAGE STEERING RIGHT (INIT 04 11) to the
same value (so that you know what voltage the valve re-
ceives when tested) and test to see what voltage is just ca-
1
pable of starting to turn the wheel. You should stand on the
footplate of the machine to see what happens. This voltage
is the right level for START VOLTAGE STEERING RIGHT.
4. Repeat point 3 for START VOLTAGE STEERING LEFT (INIT
04 12). There can be a slight difference between the different
5
2 directions.
5. Adjust the END VOLTAGE STEERING LEFT (INIT 04 13)
and RIGHT (INIT 04 11) to obtain the “right” steering speed.
3 Stand on the footplate and observe how the wheels move
Max when steered to full lock. They should move at approximately
100% 4 0
the same speed as rapid turning of the steering wheel (1- 1.5
turns of the steering wheel per second).
6. It can happen that the wheels will turn by themselves. This is
1. END VOLTAGE STEERING counteracted by increasing the DEAD ZONE WHEEL AN-
(INIT 04 11/INIT 04 13)
2. START VOLTAGE
GLE (INIT 04 9) or lowering the START VOLTAGE STEER-
(INIT 04 10/INIT 04 12) ING RIGHT & LEFT (INIT 04 10/INIT 04 12). However, only
3. Correction error minor adjustments should be made to avoid the occurrence
4. P Factor (INIT 04 8) of other problems, see point 7. You can also try increasing
5. DEAD ZONE WHEEL ANGLE (INIT 04 9) the P factor.
7. If the machine “pulls” in one direction this means that it has
not been correctly calibrated, or that the DEAD ZONE
WHEEL ANGLE (INIT 04 9) is to great, or that theSTART
VOLTAGE STEERING RIGHT & LEFT (INIT 04 10/INIT 04
12) is too low.
8. If the machine does not correct itself quickly enough after a
turn, the P factor should be lowered. This means that the
ECU will feed out full END VOLTAGE over a longer period of
time and will only start to regulate the voltage later. See illus-
tration. If this does not help, try increasing the END VOLT-
AGE STEERING RIGHT & LEFT (INIT 04 11/INIT 04 13).
9. Test drive the machine at different speeds and adjust the
BREAKPOINT 1-3 parameters (INIT 04 3-5) and PERCENT-
AGE AT BP2 (INIT 04 6) and BP3 (INIT 04 7).
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 04 Lever steering Group 20 P. 23

Calibration
If a fault occurs, or when, for example, the steering lever or wheel
angle sensor is replaced, the system must be re-calibrated.
Study the menu overview under ECS, Terminal.
Switch between sub-menus using the RIGHT/LEFT arrow keys.
CALIBR OF MODULE 04 Use the +/- buttons to increase or decrease the set values.
LEVER STEERING Save the new value by pressing ENTER.
ENTER ! Switch to the CALIBRATION menu with arrow RIGHT/LEFT
Press ENTER to start calibration.

1. Do not touch the steering lever when the central position is

CALIBR 04 1(7)
STEERING LEVER XXXX being calibrated. The terminal displays the steering lever’s
TO CENTRE XXXX central position. Press ENTER to save this value as “central
POSITION position”.

CALIBR 04 2(7) 2. Move the lever as far to the left as possible. The terminal dis-
STEERING LEVER XXXX plays the steering lever’s position. Press ENTER to save this
TO LEFT XXXX
POSITION value.

CALIBR 04 3(7)
STEERING LEVER XXXX 3. Move the lever as far to the right as possible. The terminal
TO RIGHT XXXX displays the steering lever’s position. Press ENTER to save
POSITION this value.

CALIBR 04 4(7) 4. Adjust the position of the wheels until they are parallel with
SET WHEELS IN XXXX
CENTRE POSITION XXXX the truck. The terminal displays the position of the wheels.
Press ENTER to save this value.

CALIBR 04 5(7) 5. Adjust the wheels until they are at the maximum right posi-
SET WHEELS MAX XXXX tion. The terminal displays the position of the wheels. Press
TO RIGHT POS XXXX ENTER to save this value.

CALIBR 04 6(7) 6. Adjust the wheels until they are at the maximum left position.
SET WHEELS MAX XXXX
TO LEFT POS XXXX The terminal displays the position of the wheels. Press EN-
TER to save this value.

CALIBR 04 7(7)
CALIBRATION OF
STEERING LEVER DONE 7. Press ENTER to conclude calibration.
ENTER

CALIBR OF MODULE 04 ! Move on using the RIGHT/LEFT arrow keys.

LEVER STEERING ! Alternatively. Press the RIGHT/LEFT arrow keys to access
ENTER the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 06 Micro steering Group 20 P. 24

Initiation of module 0 6
(Trucks supplied before 98-05-18 )
Study the menu overview under ECS, Terminal.
INITIATION MODULE 06 Switch between sub-menus using the RIGHT/LEFT arrow keys.
MICRO STEERING Use the +/- buttons to increase or decrease the set values.
Save the new value by pressing ENTER.
ENTER

INIT 06 1(8) 1. Nominal value 50. Setting of break point 1 (BP 1). Affects
NEW VALUE XXX.X the steering characteristics. see Technical Handbook ECS
BREAK POINT 1 XXX.X DCD 90-450, Lever steering characteristics section under 04
KM/H Lever steering (applies to points 1-5).

INIT 06 2(8) 2. Nominal value 100. Setting of break point 2 (BP 2).
NEW VALUE XXX.X
BREAK POINT 2 XXX.X
KM/H

INIT 06 3(8)
NEW VALUE XXX.X 3. Nominal value 150. Setting of break point 3 (BP 3).
BREAK POINT 3 XXX.X
KM/H

INIT 06 4(8)
NEW VALUE XXXX 4. Nominal value 90. Percentage of maximum steering capa-
PERCENT AT BP 2 XXXX
bility at BP 2.

INIT 06 5(8)
NEW VALUE XXXX 5. Nominal value 80. Percentage of maximum steering capa-
PERCENT AT BP 3 XXXX bility at BP 3.

INIT 06 6(8) 6. Nominal 80. If min. current increases, the valve starts to
NEW VALUE XXXX open, i.e., the wheels start to deflect. Min. current should be
MIN VOLTAGE TO XXXX set so that the wheels do not move when the truck is station-
STEERING VALVE
ary with the engine running.

INIT 06 7(8)
NEW VALUE XX 7. Nominal 165. Maximum current out to the steering
MAX VOLTAGE TO XXX valve. Adjusted on valve replacement.
STEERING VALVE

INIT 06 8(8)
INITIATION MODULE 06 8. Initiation of module 06 completed.
COMPLETED
ENTER Press ENTER to return to initiation start menu.

INITIATION MODULE 06 ! Move on using the RIGHT/LEFT arrow keys.

MICRO STEERING
! Alternatively. Press the RIGHT/LEFT arrow keys to access
ENTER the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0006
DCD40-500/ECD40-90L ECU 1 00-12
ECS SERVICE 06 Micro steering Group 20 P. 25

Initiation of module 06
INITIALIZE MODULE 06 (Trucks supplied after 98-05-18)
STEERING
Study the menu overviews under ECS, Terminal.
ENTER Scroll through the sub-menus with arrow RIGHT/LEFT. Increase/
decrease set values with +/-. Save new values with ENTER.
! Switch to the INITIATION menu with arrow RIGHT. Press
INIT 06 1(14) ENTER.

NOT USED 1. Not used.

INIT 06 2(14)
2. Not used.
NOT USED

INIT 06 3(14) 3. Nominal value 5. Setting of break point 1 (BP 1). Affects the
XXX.X
BREAK POINT XXX.X characteristics of the steering, see Technical Handbook ECS
BP1 km/h DCD 90-450, Lever steering characteristics section under 04
Lever steering (applies to points 3-7).
INIT 06 4(14)
XXX.X 4. Nominal value 10. Setting of break point 2 (BP 2).
BREAK POINT XXX.X
BP2 km/h

INIT 06 5(14) 5. Nominal value 15. Setting of break point 3 (BP 3).
XXX.X
BREAK POINT XXX.X
BP3 km/h

INIT 06 6(14)
XXXX 6. Nominal value 80. Percentage of max. steering capability at
PERCENT AT BP2XXXX BP 2.

INIT 06 7(14) 7. Nominal value 60. Percentage of max. steering capability at

XXXX BP 3.
PERCENT AT BP3XXXX
8. Nominal value 5. P-factor. Register how many revolutions of
the micro-steering wheel should correspond to normal steer-
INIT 06 8(14) ing wheel movement. The nominal value is for the number of
XXXX
P-FACTOR XXXX revolutions of the micro-steering wheel to correspond to the
same number of revolutions of the normal steering wheel .
A lower value gives more revolutions for the same wheel dis-
INIT 06 9(14) placement.

NOT USED 9. Not used.

INIT 06 10(14) 10. Nominal value 140-160. Set the start and stop voltages
XXXX
START VOLTAGE XXXX (menus 10 and 11) to a value, the same value for start and
STEERING RIGHT stop, so that the wheels just begin to move. The set the start
voltage to one unit less than this value.
INIT 06 11(14)
XXXX 11. Nominal value 190-210. Move the steering lever to its max-
END VOLTAGE XXXX imum position and set a value for the stop voltage. The high-
STEERING RIGHT
er the value, the faster the wheel displacement. Adjust the
value of the stop voltage so that the required steering char-
acteristics are achieved.
Continued on next page

DCD40-500/ECD40-90L
ECS SERVICE
INIT 06 12(14)
XXXX
START VOLTAGE XXXX
STEERING LEFT
INIT 06 13(14)
XXXX
END VOLTAGE XXXX
STEERING LEFT
INIT 06 14(14)
INITIATION MODULE 06
COMPLETED
ENTER
INITIALIZE MODULE 06
STEERING
ENTER
WARNING!
Don’t forget to test drive the machine in
different situations. The setting of the
start voltages is very sensitive. It must
be possible to steer the machine even
when the steering wheel is turned slow-
ly, otherwise it will not be possible to
steer straight at full speed.
The result will then be that when the
steering wheel is turned normally, the
wheels do not turn, when the speed of
turning the steering wheel is increased,
the wheels turn too much. The reason is
then that the start voltage is set too low.
If, on the other hand, the start voltage is
set too high, the machine will feel un-
easy at high speed. It will not be possi-
ble to steer carefully - the slightest turn
of the steering wheel will result in an ex-
cessive turn of the wheels.
0006
ECU 1 00-12
06 Micro steering Group 20 P. 26
12. Same setting as menu 10, but for left movement.
13. Same setting as menu 11, but for left movement.
14. Initiation module 06 completed.
Press ENTER to return to the Initiation start menu.
! Switch to the CALIBRATION menu with arrow RIGHT.
Alternately, press the RIGHT/LEFT arrow keys to access
the RETURN TO THE MAIN MENU display
Press ENTER to return to the KALMAR INDUSTRIES
SERVICE main menu
Parameter adjustment
1. Set the P factor (INIT 06 8) to a value between 3 and 8. A
higher value gives fewer turns of the steering wheel.
2. Set the START VOLTAGE STEERING LEFT (INIT 06 12) and
the END VOLTAGE STEERING LEFT (INIT 06 13) to 80
(150). Set the start and stop voltages to the same value so
that you know exactly what voltage the control valve re-
ceives. Steer carefully to the left. If the wheels do not react
correctly, increase both voltages slightly and try again. When
you do this, you must stand beside the machine in order to
assess how the wheels move. When the right level has been
found, the wheels turn slowly when the steering wheel is
turned slowly (approx. one turn of the steering wheel in 5
seconds). This is then the correct voltage for the START
VOLTAGE STEERING LEFT.
3. Repeat point 2 for START VOLTAGE STEERING RIGHT
(INIT 06 10). There can be a slight difference between the
different directions.
N.B. It should move at the same speed in both directions
4. Set the END VOLTAGE STEERING RIGHT (INIT 06 11) to
110 (195) and then adjust the END VOLTAGE STEERING
LEFT (INIT 06 13) so that the machine steers at approxi-
mately the same speed in both directions when the steering
wheel is turned quickly (approx. one turn of the steering
wheel per second). When you do this, you must stand beside
the machine in order to assess how the wheels move.Test
drive the machine and try to assess if the steering effect is
sufficient at low speeds - can you turn quickly enough? If not,
increase the END VOLTAGES and try again.
 0006
DCD40-500/ECD40-90L ECU 4 00-12
ECS SERVICE 08 El-Servo Group 20 P. 27

ECU 4 SETUP and initiation of module 0 8

Study the menu overview under ECS, Terminal.
Switch between sub-menus using the RIGHT/LEFT arrow keys.
KALMAR INDUSTRIES Use the +/- buttons to increase or decrease the set values.
SERVICE Save the new value by pressing ENTER.
! Switch to the SERVICE menu using the RIGHT/LEFT arrow
ENTER
keys.
Press ENTER.

! Register code 4. (The code can be found on the list supplied

ENTER CODE X by KALMAR)
ENTER=RETURN Press ENTER.

! Press ENTER.
SETUP/INIT M08
ELSERVO
ENTER

1(17) 1. Not used. Press arrow RIGHT.

2. Register the value for the machine’s modules on line 3.

Save by pressing ENTER.
M08 SETUP 2(17)
MODULES IN XXXX The value is the sum of the values for the modules with which
ECU1 XXXX the machine is equipped. This figure determines which men-
0-15 us are shown on the ECS terminal display.
The values for the modules are obtained through KALMAR.
Switch menus with arrow RIGHT.
3. Register the number of levers. This figure determines the
M08 INIT 3(17) number of levers to be calibrated on the CALIBRATION 1 (8)
NUMBER OF XXXX menu.
HYDRAULIC XXXX Save by pressing ENTER. Switch menus with arrow RIGHT.
FUNCTIONS 0-5

4. Register the value for the machine’s options.

M08 INIT 4(17) Save by pressing ENTER. Switch menus with arrow RIGHT.
XXXX The value for the options can be obtained from KALMAR.
OPTION M08 XXXX
0-255

5. Register a value for the amount of steering lever movement

around the central position that is still to be considered its
M08 INIT 5(17)
XXXX central position. Nominal value 50.
DEAD ZONE XXXX (50 corresponds to approx. 0.5 V.)
LEVERS 0-255

M08 INIT 6(17)

6. Register the value for start voltage.
XXXX F1 applies to both lift and lower. Nominal value 65.
F1 START XXXX
VOLTAGE 0-255

M08 INIT 7(17) 7. Nominal value 175.

XXXX
F1 END (UP) XXXX
VOLTAGE 0-255

Continued on next page

 0006
DCD40-500/ECD40-90L ECU 4 00-12
ECS SERVICE 08 El-Servo Group 20 P. 28

End voltage

M08 INIT 8(17)

XXXX 8. Nominal value 150. Start voltage
F1 END (DOWN)
VOLTAGE 0-255 Kl995GB Steering lever movement

Dead zone
M08 INIT 9(17)
XXXX
F2 START XXXX 9. Nominal value 32.
VOLTAGE 0-127

M08 INIT 10(17)

XXXX
F2 END XXXX 10. Nominal value 85.
VOLTAGE 0-127

M08 INIT 11(17)

XXXX 11. Nominal value 65.
F3 START XXXX
VOLTAGE 0-255

M08 INIT 12(17)

XXXX 12. Nominal value 175.
F3 END XXXX
VOLTAGE 0-255

M08 INIT 13(17)

XXXX
F4 START XXXX 13. Nominal value 32.
VOLTAGE 0-127

M08 INIT 14(17)

XXXX 14. Nominal value 85.
F4 END XXXX
VOLTAGE 0-127

M08 INIT 15(17)

XXXX 15. Nominal value 65.
F5 START XXXX
VOLTAGE 0-255

M08 INIT 16(17)

XXXX
F5 END XXXX 16. Nominal value 175.
VOLTAGE 0-255

Continued on next page

 0006
DCD40-500/ECD40-90L ECU 4 00-12
ECS SERVICE 08 El-Servo Group 20 P. 29

M08 INIT 17(21) 17. Only ECD

XXXX
PUMP SPEED XXXX Nominal value 55.
F2 0-100

M08 INIT 18(21)

XXXX 18. Only ECD
PUMP SPEED XXXX Nominal value 45.
F3 0-100

M08 INIT 19(21)

XXXX
PUMP SPEED XXXX 19. Only ECD
F4 0-100 Nominal value 45.

M08 INIT 20(21)

XXXX 20. Only ECD
PUMP SPEED XXXX Nominal value 45.
F5 0-100

M08 INIT 21(21) 21. Initiation of module 08 completed.

Press ENTER to return to the initiation start menu.
M08 SETUP/INIT
COMPLETED ENTER

! Move on using the RIGHT/LEFT arrow keys.

SETUP/INIT M08 ! Alternatively. Press the RIGHT/LEFT arrow keys to access
ELSERVO
ENTER the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0006
DCD40-500/ECD40-90L ECU 4 00-12
ECS SERVICE 08 El-Servo Group 20 P. 30

Calibration
Study the menu overview under ECS, Terminal.
CALIBR M08 Switch between sub-menus using the RIGHT/LEFT arrow keys.
ELSERVO
ENTER Use the +/- buttons to increase or decrease the set values.
Save the new value by pressing ENTER.
! Switch to the CALIBRATION menu using the RIGHT/LEFT
arrow keys.
CALIBR M08 1(8) Press ENTER to start calibration.
LEVERS CENTER POS.
F1X F2X F3X F4X F5X 1. Press ENTER and the indicator lamp for the corresponding
number of levers lights up. The signal is between 4-5V.

CALIBR M08 2(8)

XXXX
BALANCE XXXX 2. Applies to module 12. Press ENTER to calibrate the balance.
MACHINE WITHOUT LOAD

CALIBR M08 3(8)

XXXXXXX.Xt 3. Use the +/- buttons to increase or decrease the values to the
BALANCE XXXXXXX.Xt known weight. Save by pressing ENTER.
MACHINE WITH LOAD

CALIBR M08 4(8)

NEW VALUE 0
NOT USED 0 4. Not used. Press RIGHT arrow.

CALIBR M08 5(8)

NEW VALUE 0 5. Not used. Press RIGHT arrow.
NOT USED 0

CALIBR M08 6(8)

NEW VALUE 0 6. Not used. Press RIGHT arrow.
NOT USED 0

CALIBR M08 7(8) 7. Not used. Press RIGHT arrow.

NEW VALUE 0
NOT USED 0

CALIBR M08 8(8) 8. Press ENTER to conclude calibration.

CALIBR M08 COMPLETED
ENTER

! Move on using the RIGHT/LEFT arrow keys.

CALIBR M08
ELSERVO ! Alternatively. Press the RIGHT/LEFT arrow keys to access
ENTER the RETURN TO THE MAIN MENU display.

Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0006
DCD40-500/ECD40-90L ECU 4 00-12
ECS SERVICE 08 El-Servo Group 20 P. 31

Diagnostics for Module 08

Study the menu overview under ECS, Terminal.
KALMAR INDUSTRIES
SERVICE ! Move to the KALMAR INDUSTRIES SERVICE main menu,
using the LEFT/RIGHT arrow keys.
ENTER ! Press ENTER
! Register code 5.
The codes can be found on the list from KALMAR.
Press ENTER.
ENTER CODE

ENTER=RETURN

DIAG SENSORS 1(11) 1. TW RELEASESensor for twist-locks, container

TW ULOCK ❒ OVERR ❒ TW LOCK Sensor for twist-locks, container
TW LOCK ❒ OPER OK ❒
ALIGNM ❒ ALIGN Sensor for alignment against container
SAFE CB Safety contact breaker, attachment
OK In-signal pin 9 = 24V *
M08 DIAGNOSE 2(11) 2. D12(9) In-signal pin 9 = 24V *
D12(9) ❒ D13(19) ❒ D14(11) In-signal pin 14 = 24V *
D14(11)❒ D15(31) ❒
D16(32)❒ D16(32) In-signal pin 16 = 24V *
D13(19) In-signal pin 13 = 24V *
D15(31) In-signal pin 15 = 24V *
M08 DIAGNOSE 3(11) *) See circuit diagrams for machine in question.

LIFT/LO LEVER5.00V 3. Voltage in to ECU from levers in cab.

TILT LEVER 5.00V
Normal (middle position) = approx. 5V.
Increases/reduces when the function is used.
M08 DIAGNOSE 4(11)
SIDE SH LEVER5.00V 4. Voltage in to ECU from levers in cab.
FUNC 4 LEVER 5.00V Normal (middle position) = approx. 5V.
FUNC 5 LEVER 5.00V
Increases/reduces when the function is used.

M08 DIAGNOS 5(11) 5. Out-signal from ECU (24V) that activates the relays for the
HYDR PUMP ACTIVE ❒ hydraulic functions.
LOWERING (RELAY) ❒ See circuit diagrams for the model in question.
TILT FORW (RELAY)❒

M08 DIAGNOSE 6(11) 6. Out-signal from ECU (24V) that activates the relays for the
SIDESHIFT (RELAY)❒
FUNC 4 (RELAY) ❒ hydraulic functions.
FUNC 5 (RELAY) ❒ See circuit diagrams for the model in question.

M08 DIAGNOS 7(11)

TILT (MO2, H.STAT ❒ 7. Not used.
EXTRA (MO2, H.STAT❒
SYSTEM OK ❒

M08 DIAGNOS 8(11)

LIFT VALVE 0.00V 8. Voltage out to valves for respective hydraulic functions.
LOWER. VALVE 0.00V
TILT VALVE 0.00V

Continued on next page

 0006
DCD40-500/ECD40-90L ECU 4 00-12
ECS SERVICE 08 El-Servo Group 20 P. 32

M08 DIAGNOSE 9(11) 9. Voltage out to valves for respective hydraulic functions.
SIDESHIFT VALVE0.00V
FUNC.4 VALVE 0.00V
FUNC.5 VALVE 0.00V

M08 DIAGNOSE10(11) 10. Not used.

PUMP SPEED (EC)0.00V

LIFT (MO2) 0.00V

M08 DIAGNOSE11(11) ! Move on by using the RIGHT/LEFT arrow keys.

RETURN TO MAIN MENU ! Press ENTER to come to the KALMAR INDUSTRIES
SERVICE main menu.
ENTER