GB

Publ. No. 923862-0014 00-08

Technical Handbook
ECS SERVICE
DRD100-200
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ContChamp DRD100-200 00-08
ECS SERVICE Contents Group 20 P. 1

Contents

ECS
Overview .............................................................................. 2
Terminal ............................................................................... 3
Terminal functions ........................................................... 3
Menu structure ................................................................ 3
Operating menus............................................................. 4
Error messages ............................................................... 6
Service menus............................................................... 11
ECU 1
SETUP ............................................................................... 13
01 Automatic gear changing............................................... 14
Initiation of module 01 ................................................... 14
Throttle settings............................................................. 15
Calibration ..................................................................... 16
04 Lever steering 17
Initiation of module 04 .................................................. 17
Calibration ..................................................................... 19
06 Mini steering .................................................................. 20
Initiation of module 06 .................................................. 20
ECU 5
SETUP, el-servo................................................................. 22
80 Electronic overload protection ....................................... 25
Calibration, Duplex boom ............................................. 25
Calibration, Triplex boom .............................................. 27
Diagnosis............................................................................ 29
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Overview Group 20 P. 2

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
one, two or three central computer units, ECU 1, ECU 5 and
ECU 9. A terminal display in the operator’s cab shows current val-
ues and generates an alarm if the values exceed the pro-
grammed tolerances.
! ECU 1 is used for different additional modules, such as
01 Automatic Gear Changing, 04 Lever Steering, 06 Mini
steering and 07 Monitoring.
! ECU 5 is mandatory and is used to control the El-Servo cir-
cuits. ECU 5 also contains the overload protection function.
! ECU 9 is used for tilt control and for controlling the functions
of the bottom lift.

ECU 1 1) ECU 5 ECU 9 1)

01 Automatic El-Servo (standard) 56 Cab move-

Gear Changing 1) 53 Damping lock 1) ment 1)
04 Lever Steering 1) 54 Tilt 1)
58 Container Counter 1)
06 Mini steering 1)
70 PC/Printer 1)
07 Monitoring 1) 80 Overload
1 protection system 1)

5 1) Optional equipment
ECU

The ECS:
– provides torque controlled automatic gear changing
(Module 01)
CONT CHAMP – provides electro-hydraulic lever steering with or without
wheel return (Module 04)
KL942 – provides electro-hydraulic steering with mini steering wheel
(Module 06)
– monitors the engine and gearbox to ensure reasonable op-
erating conditions (Module 01)
– monitors the components in the system, e.g., sensors, to
ensure their correct function (Module 07)
– interrupts hydraulic functions when overload of the steering
axle occurs (Module 80)
– controls vertical lift and balance (standard el-servo)
– adapts the speed of movement of the BOOM OUT function
in relation to the load and adapts the speed of movement of
the LOWER function in relation to boom extension and load
(standard el-servo)

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.
 0014
ContChamp DRD100-200 ECS 00-08
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.
4. - is used to decrease a value.
F
5. + is used to increase a value.
4 3 2 1

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

L 0
R
new values when setting up and calibrating the system.
KL580B
R
Access to the service menus also requires the use of special
1 2 3
codes, that are separately obtainable from KALMAR.
4 5
7. A red warning light blinks in the event of an error and is ex-
tinguished when reset by pressing button 3.
8. The terminal display has 4 lines with space for 20 characters
on each line. Graphical presentation of operating menus and
R error messages.
1 2 3
Menu structure
4 5 There are three types of menus
1. Operating menus
The operating menus are accessible to the operator. The
6 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 Overload indicator.
2. Error messages
Displayed automatically and have priority over other menus.
3. Service menus
The operating menu loop always contains the KALMAR IN-
DUSTRIES 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.

1.
1. 1.

1.

KL1414
1.

Enter
2.
3.

3.
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 4

01 Automatic gear changing
07 Monitoring
80 Overload protection system
Operating menus
The menus that are displayed on the terminal depend on the
modules with which the truck’s ECS is equipped. The overview
below shows the possible combinations. Use either arrow
RIGHT/LEFT to switch between menus. All operating menus are
in a connected loop.

N.B. Additional menus may occur as a result of adaptation to spe-

cific customer requirements.

80

2 1
4

01.80

3 1
4

07.80
01.07.80 8
9 7

1 6

5
3 4

KL1413

Explanations, see next page

Operating menus with electronic overload protection, module 80

 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 5

Operating menus, module 80

Modul 80 overload protection function, under normal conditions,
functions as a balance and gives a continual reading of the size
1 and position of the load.
1. Main menu KALMAR INDUSTRIES SERVICE

2. Normal operating condition, module 80.

a. 1750 rpm Engine speed, r/min
c. 3.0 m Distance between the front edge of the
wheels and the centre of gravity of the load.
a d. 25.5 t Current load in tonnes
2 c e. Indicator showing steering axle load, fills the display to the
d left for 95-100% of the permitted load. When the indicator
reads full, the system interrupts operation due to overloading
e of the steering axle. The red warning lamp blinks.
f It is not possible to switch to other menus until the overload
is rectified.
a f. Load indicator, fills the display to the right for 0-100% loads.
3 When the load indicator reads full, the system interrupts op-
b
c eration due to forward overload.
The red warning lamp lights continually.
d
It is not possible to switch to other menus until the overload
has been rectified.
e
f 3. Normal operating condition,
module 80 + module 01 + module 07
a a. 1750 rpm Engine speed r/min
4 b. F3 Current gear
b
c c. d. e. f. See menu 2 explanation above.
d 4. a. 10.38 t Current load in tonnes
b. 1.07 m Boom extension
c. 3.08 m Lc-distance. Distance between drive axle
a centre and load centre.
5 b d. 23.0 ° Boom angle
c
d 5. a. 1750 rpm Engine speed r/min
b. F3 Current gear
c. 14 km/h Current speed
a d. Fuel level. The tank is full when the indicator is filled
6 to the right.

6. a. 75 °C Engine coolant temperature

b b. 3.8 bar Engine oil pressure

a
7 7. a. 75 °C Gearbox oil temperature
b. 3.8 bar Gearbox oil pressure

8 a
8. a. 24.5 v Battery voltage
b b. 75 °C Hydraulic oil temperature

a
9 9. a. 28756:21.54 h.Total operating time, h: min. sec.
b. 130h Time to next service, h
b
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 6

Error messages
If two faults occur at the same time, the terminal displays the fault
with the highest priority.
Error messages always have higher priority than normal menus.
Faults 01-08 are level 2 faults and cannot be reset before the fault
is rectified.
The first two figures show to which module the error message re-
lates
(These figures are not shown on the display)
01 = Automatic gear changing
07 = Monitoring
04 = Lever Steering
06 = Micro-steering
80 = Overload protection system

01, 07 01 01. Battery voltage very low/high

Stop as soon as possible and contact service.

01, 07 02 02. Faulty signal from accelerator sensor.

Engine speed reduction.
Stop as soon as possible and contact service.

01, 07 03 03. Faulty signal from injection pump motor sensor.

Engine speed reduction.
Stop as soon as possible and contact service.

01, 07 04
04. Gear lever not functioning.
Engine speed reduction.
Stop as soon as possible and contact service.

07 05 05. Engine oil pressure extremely low.

Engine speed reduction.
Stop as soon as possible and contact service.

07 06
06. Coolant temperature extremely high.
Engine speed reduction.
Stop as soon as possible and contact service.

07 07 07. Gearbox oil pressure extremely low.

Engine speed reduction.
Stop as soon as possible and contact service.

07 08
08. Gearbox oil temperature extremely high.
Engine speed reduction.
Stop as soon as possible and contact service.
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 7

09. Faulty signal from engine rev sensor.

01, 07 09 Engine speed reduction.
Stop as soon as possible and contact service.

07 10 10. Low engine oil pressure.

Check oil level and top up as required.

07 11
11. High coolant temperature.
Check coolant level and top up as required.

07 12
12. Low gearbox oil pressure.
Check oil level and top up as required.

07 13 13. High gearbox oil temperature.

Check oil level and top up as required.

07 14
14. Fuel level extremely low.
Fill the tank to avoid air in the system.

07 15
15. Low coolant level.
Top up the coolant fluid.

07 16
16. High hydraulic oil temperature.
Operation possible.
Contact service.

07 17
17. Faulty signal from fuel gauge sensor.
Operation possible.
Contact service.

07 18
18. Faulty signal from gearbox oil pressure sensor.
Operation possible.
Contact service.
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 8

19. Faulty signal from engine oil pressure sensor.

07 19 Operation possible.
Contact service

07 20 20. Faulty signal from coolant temperature sensor.

Operation possible.
Contact service.

07 21
21. Faulty signal from gearbox oil temperature sensor.
Operation possible.
Contact service.

07 22
22. Faulty signal from hydraulic oil temperature sensor.
Operation possible.
Contact service.

07 23
23. Service interval exceeded.
Contact service as soon as possible.

01, 07 24
24. Faulty signal from prop shaft rpm sensor
Engine speed reduction.
Stop as soon as possible and contact service.

04 25 25. Steering lever fault.

Switch off the steering system.
Contact service as soon as possible.

04 26 26. Faulty signal from steering sensor.

Switch off the steering system.
Contact service as soon as possible.

06 27
27. Faulty signal from mini steering sensor.
Switch off the steering system.
Contact service as soon as possible.

07 28
28. Warning! Low brake pressure.
Contact service as soon as possible.
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 9

- 31 31. System fault ECU 1.

Contact service as soon as possible.

- 35
35. System fault ECU 5.
Contact service as soon as possible.

07 50
50. Battery voltage very low/high.
Contact service as soon as possible.

- 52 52. Communication with ECU 1 broken.

First try switching off and then re-starting the engine!
If the fault remains, contact service as soon as possible.

80 53
53. Faulty signal from angle sensor
Stop as soon as possible and contact service.

80 54
54. Faulty signal from length sensor.
Stop as soon as possible and check the sensor wire.
Contact service if the fault remains.

80 55 55. Faulty signal from pressure sensor, return line for left and
right lift cylinders. The balance is out if range.
Stop as soon as possible and contact service.

80 56
56. Faulty signal from pressure sensor, feed line for left
lift cylinder.
Stop as soon as possible and contact service.

80 57
57. Faulty signal from pressure sensor, feed line for right
lift cylinder.
Stop as soon as possible and contact service.

80 58 58. Faulty analog signal from joystick.

All boom functions are interrupted.
Stop as soon as possible and contact service.
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 10

60 60. Faulty signal from twist-locks sensors.

80 Applies to both locked and unlocked position.
Stop as soon as possible and contact service.

62. The Module 80 errors 53, 54, 67, 57 will activate error menu
80 62
62.
When error menu 62 is activated:
Warning lamp on the ECS-terminal lights up

When pressing RESET:

Menu 62 starts blinking, 5 sec ON and 5 sec OFF
The hydraulic functions LIFT/LOWER and BOOM OUT/IN
are operative but at a lower speed.
 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 11

Service menus
All service sub-menus are accessible from the main
KALMAR INDUSTRIES SERVICE menu, thereafter, a code must
be registered. There are four different codes, codes 1, 2, 3 and 4.
! Code 1 leads to the SETUP, INITIATION and CALIBRATION
of the modules in ECU1.
! Code 2 leads to the INITIATION of the El-servo in ECU 5.
! Code 3 leads to the CALIBRATION of module 80 in ECU 5.
! Code 4 leads to the DIAGNOSIS menus.
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.

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 I N I T I A T I O N MO D U L E 0 6
W HE E L P O S I T I ON M I N I S T E E R I N G
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 MO D U L E E0 N4 T E R
L E V E R 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 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 N T 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 04/06 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

KL1433GB 5 4

Service menus under Code 1

 0014
ContChamp DRD100-200 ECS 00-08
ECS SERVICE Terminal Group 20 P. 12

Code 2 Code 3

Code 4
19 20 1 2 3 15 16 1 2 3
18 4 14 4
17 5
16 SETUP EL-SERVO 6 13 CALIBRATION 5
ECU5 MODULE 80
15 7 6
12
14 9 8 11 7
13 12 11 10 10 9 8
KL1434GB

10 1 2 3
9
DIAGNOSIS 4
8 5
7 6

SETUP 1(5)
XXXX
REV INTERLOCK XXXX
0=LO 1=MED 2=HI

SETUP 2(5)
XXXX
MODULES ECU1 XXXX
Detailed information about the different serv-
ice menu paths can be found under respective
section descriptions.
SETUP 3(5) The connected loops then appear as shown in
XXXX the adjacent picture.
DATA SET XXXX
TRANSMISSION The arrows beside the menus show the switch
paths between menus. Use RIGHT/LEFT ar-
row keys.
SETUP 4(5)
XXXX
DATA SET ENGINE XXXX

SETUP 5(5)
SETUP COMPLETED

ENTER

Service menus under Codes 2, 3 & 4

 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE SETUP Group 20 P. 13

ECU 1 SETUP, setting nominal values

Study the menu overview under ECS, Terminal
! Switch to the SERVICE menu using arrow RIGHT (or LEFT)
Press ENTER

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

by KALMAR)
Press ENTER

SETUP ! Press ENTER

BASIC SETTING
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
REV INTERLOCK XXXX
0=LO 1=MED 2=HI
2. Register the value for the machine’s modules on line 3.
Save by pressing ENTER.
SETUP 2(5) The value is the sum of the values for the modules with which
XXXX the machine is equipped. This figure determines which men-
MODULES ECU1 XXXX
us are shown on the ECS terminal display.
The values for the modules are obtained through KALMAR.
Switch menus with arrow RIGHT.

SETUP 3(5) 3. Register the data set number for the transmission in question
XXXX
DATA SET XXXX on line 3, see the table in the ECS section, Data sets.
TRANSMISSION Save by pressing ENTER. Switch menus with arrow RIGHT.

4. Register the data set number for the engine in question on

SETUP 4(5)
XXXX line 3, see the table in the ECS section, Data sets.
DATA SET ENGINE XXXX Save by pressing ENTER. Switch menus with arrow RIGHT.

SETUP 5(5)
SETUP COMPLETED 5. The initiation of SETUP is now completed. Press ENTER.

ENTER

SETUP
BASIC SETTING ! Press arrow RIGHT to move on to the SERVICE INTERVAL
ECU 1 menu.
ENTER

6. If the service interval is to be altered, use the + / - buttons on

the terminal.
If the service interval is to be reset and a new service interval
started, press ENTER.
 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 01 Automatic gear changing Group 20 P. 14

INITIALIZE MODULE 01
AUTOMATIC GEARCHANGE
AND ELEC ACCELERATOR
ENTER
Initiation of module 01
Study the menu overview under ECS, Terminal
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. Press
ENTER.

INIT 01 1(12) 1. Nominal value 20. Determines the timing of changing down
XX.XX through the gears. Higher value = earlier change down. Low-
SLIP FACTOR XX.XX er value = later change down, i.e., the gearbox remains in the
4>3 AND 3>2 higher gear longer.
2. Nominal value 60. 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 60. 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 15. 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 15. Determines how much power needs to
INIT 01 5(12) be applied to the injection pump motor when a small in-
XXXX
✱ POWER TO XXXX
crease in engine revolutions is required. When the accelera-
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 130. Determines how quickly engine revolu-
✱ MAX POWER XXXX tions increase when the accelerator is depressed to the floor,
TO INCR GAS XXXXrpm i.e., the speed of the throttle arm.

INIT 01 7(12) 7. Nominal value 10. Determines the maximum power re-
✱ XXXX quired by the injection pump motor to reduce throttle when
IDLING GAS XXXX the accelerator is released.
POWER

INIT 01 8(12) 8. Nominal value 0. Determines how long engine revolutions

XXXX are reduced when changing up from 2000 RPM.
GEARCHANGE TIME XXXX
AT 2000rpm

INIT 01 9(12) 9. Nominal value 0. Determines how long engine revolutions

XXXX are reduced when changing up from 1400 RPM.
GEARCHANGE TIME XXXX N.B. Menu 9 must have the same or higher value than menu
AT 1400rpm 8.
INIT 01 10(12)
XXXX 10. The defined value limits the speed of the machine, in kph.
SPEED LIMIT XXXX
0=NO LIMIT

INIT 01 11(12) 11. 0 = normal gear changing

XXXX
START IN 2ND XXXX 1 = start in 2nd. Only when gear lever is in position 4.
GEAR 1=2ND If the gear lever is in position 3, this function does not apply.

Continued
on next page

✱ = Not used at EDC-engine

 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 01 Automatic gear changing Group 20 P. 15

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

INITIALIZE MODULE 01
AUTOMATIC GEARCHANGE ! Press arrow RIGHT to move on to the CALIBRATION menu
AND ELEC ACCELERATOR
ENTER

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.

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

4. Still in menu 6, kick-down from 0 throttle to max throttle and

INIT 01 5(12)
XXXX check that the engine revs to a maximum of 2300 rpm.
POWER TO XXXX Note: The values in menus 5 and 6 may be such that you
INCREASE GAS must choose between a slight over-run or a slight reduction
of maximum revs.
INIT 01 6(12)
XXXX 5. Switch to menu 4. Reduce the value as much as is possible.
MAX POWER XXXX Depress and release the accelerator and check that the cor-
TO INCR GAS XXXXrpm
responding increase and decrease in throttle occurs.

INIT 01 7(12) 6. Switch to menu 7. Reduce the value so that even when the
XXXX
IDLING GAS XXXX accelerator is released very slowly to 0, the engine revs de-
POWER 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.
 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 01 Automatic gear changing Group 20 P. 16

CALIBR OF MODULE 01
INJECTOR PUMP MOTOR
AND ACCELERATOR
ENTER
Calibration of module 01
Study the menu overview under ECS, Terminal
When a new accelerator pedal or injection pump motor is in-
stalled, minimum and maximum values must be calibrated. The
engine should be switched off, but the ignition ON.
Note. If, for example, only the accelerator is to be calibrated, do
not skip the menu using arrow RIGHT/LEFT.
! Switch to the CALIBRATION menu with arrow RIGHT.
Press 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 7. Press ENTER to conclude calibration.
INJECTION PUMP MOTOR
ACCELERATOR OK ENTER

CALIBR OF MODULE 01
INJECTOR PUMP MOTOR ! Press arrow RIGHT to move on to INITIATION 04/06 or
AND ACCELERATOR RETURN TO MAIN MEU.
ENTER

✱ = Not used at EDC-engine

 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 04 Lever steering Group 20 P. 17

Initiation module 04
INITIALIZE MODULE 04 Study the menu overviews under ECS, Terminal.
STEERING
Scroll through the sub-menus with arrow RIGHT/LEFT. Increase/
ENTER decrease set values with +/-. Save new values with ENTER.
! Switch to the INITIATION menu with arrow RIGHT. Press
ENTER.
INIT 04 1(14) 1. Register the sensitivity of the steering lever.
XXXX 0 = wheel displacement in direct relationship to lever move-
CHARACTER LEVERXXXX ment through the whole range of lever movement
0-31, 0=LIN 32 = wheel displacement is less at the start of lever move-
ment and greater at the end of the movement
INIT 04 2(14)

Output signal
0
XXXX
TYPE OF STEERINGXXXX
0=NO FEEDBACK
32

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

INIT 04 4(14) KL1116

XXX.X Lever movement

BREAK POINT XXX.X
BP2 km/h 2. Select wheel return or non-return system.
0 = Wheel return system.
1 = Non-return system.
INIT 04 5(14)
XXX.X
BREAK POINT XXX.X 3. Nominal value 50. Setting of break point 1 (BP 1). Affects
BP3 km/h the characteristics of the steering, see Technical Handbook
DRD, group 20, Lever steering characteristics section under
04 Lever steering (applies to points 3-7).
INIT 04 6(14)
XXXX
PERCENT AT BP2XXXX 4. Nominal value 100. Setting of break point 2 (BP 2).

5. Nominal value 150. Setting of break point 3 (BP 3).

INIT 04 7(14)
XXXX
PERCENT AT BP3XXXX 6. Nominal value 65. Percentage of max. steering capability at
BP 2.

INIT 04 8(14) 7. Nominal value 40. Percentage of max. steering capability at

XXXX BP 3. (Only applies to wheel return systems).
P-FACTOR XXXX
8. Nominal value 50. P-factor.
INIT 04 9(14) (Only applies to wheel return systems)
XXXX
DEAD ZONE XXXX 9. Nominal value 0. Determines the acceptable wheel angle
WHEEL ANGLE
when steering begins. Not normally altered.
(Only applies to wheel return systems).
INIT 04 10(14)
XXXX
START VOLTAGE XXXX 10. Nominal value 60-80. Set the start and stop voltage (menus
STEERING RIGHT 10 and 11) to a value, the same value for start and stop, so
that the wheels just begin to move. Then set the start voltage
to one unit less than this value.
INIT 04 11(14)
XXXX
END VOLTAGE XXXX 11. Nominal value 100-150. Move the steering lever to maxi-
STEERING RIGHT mum position and set a value for stop voltage. The higher the
value, the faster the wheel displacement. Adjust the value for
the stop voltage so that the required steering characteristics
are achieved.
Continued on next page
 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 04 Lever steering Group 20 P. 18

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

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

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

INITIALIZE MODULE 04
STEERING ! Switch to the CALIBRATION menu with arrow RIGHT.
ENTER
 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 04 Lever steering Group 20 P. 19

Calibration of module 04
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 overviews under ECS, Terminal
Scroll through the sub-menus with arrow RIGHT/LEFT. Increase/
CALIBR OF MODULE 04 decrease set values with +/-. Save new values with ENTER.
LEVER STEERING
! Switch to the CALIBRATION menu with arrow RIGHT
ENTER Press ENTER to start calibration.

CALIBR 04 1(7) 1. Do not touch the steering lever when the central position is
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)
STEERING LEVER XXXX 2. Move the lever as far to the left as possible. The terminal dis-
TO LEFT XXXX plays the steering lever’s position. Press ENTER to save this
POSITION value.

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

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

CALIBR 04 6(7)
SET WHEELS MAX XXXX 6. Adjust the wheels until they are at the maximum left position.
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 7. Press ENTER to conclude calibration.
STEERING LEVER DONE
ENTER

! Move on using the RIGHT/LEFT arrow keys

CALIBR OF MODULE 04
LEVER STEERING ! Alternatively, press the RIGHT/LEFT arrow keys to access
the RETURN TO MAIN MENU display.
ENTER
Press ENTER to return to the KALMAR INDUSTRIES
SERVICE main manu
 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 06 Mini steering Group 20 P. 20

Initiering av modul 06
INITIALIZE MODULE 06 Study the menu overviews under ECS, Terminal.
STEERING
Scroll through the sub-menus with arrow RIGHT/LEFT. Increase/
ENTER decrease set values with +/-. Save new values with ENTER.
! Switch to the INITIATION menu with arrow RIGHT. Press
ENTER.
INIT 06 1(14)
1. Not used.
NOT USED

INIT 06 2(14) 2. Not used.

NOT USED

3. Nominal value 50. Setting of break point 1 (BP 1). Affects

INIT 06 3(14) the characteristics of the steering, see Technical Handbook
XXX.X DRD, group 20, Lever steering characteristics section under
BREAK POINT XXX.X 04 Lever steering (applies to points 3-7).
BP1 km/h

INIT 06 4(14)
4. Nominal value 100. Setting of break point 2 (BP 2).
XXX.X
BREAK POINT XXX.X
BP2 km/h
5. Nominal value 150. Setting of break point 3 (BP 3).
INIT 06 5(14)
XXX.X
BREAK POINT XXX.X
BP3 km/h

6. Nominal value 90. Percentage of max. steering capability at

INIT 06 6(14) BP 2.
XXXX
PERCENT AT BP2XXXX

7. Nominal value 80. Percentage of max. steering capability at

BP 3.
INIT 06 7(14)
XXXX
PERCENT AT BP3XXXX 8. Nominal value 6. P-factor. Register how many revolutions of
the micro-steering wheel should correspond to normal steer-
ing wheel movement. The nominal value is for the number of
INIT 06 8(14) revolutions of the micro-steering wheel to correspond to the
XXXX same number of revolutions of the normal steering wheel .
P-FACTOR XXXX
A lower value gives more revolutions for the same wheel dis-
placement.
INIT 06 9(14)
9. Not used.
NOT USED

10. Nominal value 60-80. Set the start and stop voltages (men-
INIT 06 10(14) us 10 and 11) to a value, the same value for start and stop,
XXXX so that the wheels just begin to move. The set the start volt-
START VOLTAGE XXXX
STEERING RIGHT age to one unit less than this value.

INIT 06 11(14) 11. Nominal value 100-150. Move the steering lever to its max-
XXXX imum position and set a value for the stop voltage. The high-
END VOLTAGE XXXX er the value, the faster the wheel displacement. Adjust the
STEERING RIGHT value of the stop voltage so that the required steering char-
acteristics are achieved.

Continued on next page

 0014
ContChamp DRD100-200 ECU 1 00-08
ECS SERVICE 06 Mini steering Group 20 P. 21

INIT 06 12(14)
XXXX
START VOLTAGE XXXX 12. Same setting as menu 10, but for left movement .
STEERING LEFT

INIT 06 13(14)
XXXX
END VOLTAGE XXXX 13. Same setting as menu 11, but for left movement.
STEERING LEFT

INIT 06 14(14)
INITIATION MODULE 06
COMPLETED 14. Initiation module 06 completed.
ENTER Press ENTER to return to the Initiation start menu.

INITIALIZE MODULE 06
STEERING ! Switch to the CALIBRATION menu with arrow RIGHT.
Alternately, 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
 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE SETUP Group 20 P. 22

SETUP, el-servo
Allow the machine to run for at least 15 minutes before carrying
out SETUP. Study the menu overviews under ECS, Terminal

! Switch to the SERVICE menu with arrow RIGHT/LEFT

! Enter code 2. (The code is on the list from KALMAR)

Press ENTER.

SETUP SERVO 1(22)

MODULES ECU 1 XXXX 1. Register the same values shown under point 5 in the ECU 1
XXXX SETUP. Save with ENTER.

2. On line 3, register the value for the machine’s modules in

SETUP SERVO 2(22)
ECU 5.
MODULES ECU 5 XXXX The value is the sum of the values for the modules with which
XXXX the machine is equipped, for example:
A complete list can be obtained from KALMAR.

SETUP SERVO 3(22) 3. Not used.

NOT USED

SETUP SERVO 4(22) 4. Register the figure for the machine’s current load curve. This
MACHINE TYPE XXXX only applies to module 60 or 50 with electronic balance. The
XXXX figures are contained in a register at KALMAR and may not
0=S6 1=B3 2=S8
be altered without specific permission from KALMAR.

SETUP SERVO 5(22)

NOT USED 5. Not used.

SETUP SERVO 6(22) 6. Not used.

NOT USED

SETUP SERVO 7(22)

DATA SET XXXX 7. The relevant data set is shown on the list from Kalmar.
ENGINE (W) XXXX
XXXXrpm
! Within the program, menus for the return to the main menu
appear at regular intervals.
Skip these using arrow RIGHT.
RETURN TO MAIN MENU

ENTER

Continued on next page

 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE SETUP Group 20 P. 23

Menus 8-19, run the functions and save the values obtained by
pressing ENTER. The stated values are nominal values.

SETUP SERVO 8(22)

START CURRENT XXXX 8. Nominal value 240.
LIFT XXXX
200-600

SETUP SERVO 9(22)

END CURRENT XXXX 9. Nominal value 600.
LIFT XXXX
200-600

SETUP SERVO 10(22)

START CURRENT XXXX
LOWER XXXX 10. Nominal value 240.
200-600

SETUP SERVO 11(22)

END CURRENT XXXX 11. Nominal value 460.
LOWER XXXX
200-600

SETUP SERVO 12(22)

START VOLTAGE XXXX 12. Nominal value 65.
BOOM OUT XXXX
0-255

SETUP SERVO 13(22)

END VOLTAGE XXXX
BOOM OUT XXXX 13. Nominal value 135.
0-255

SETUP SERVO 14(22)

START VOLTAGE XXXX 14. Nominal value 65.
BOOM IN XXXX
0-255

SETUP SERVO 15(22)

END VOLTAGE XXXX 15. Nominal value 125.
BOOM IN XXXX
0-255

SETUP SERVO 16(22)

START CURRENT XXXX 16. Nominal value 240.
CLOCKWISE XXXX
200-600

SETUP SERVO 17(22)

END CURRENT XXXX
CLOCKWISE XXXX 17. Nominal value 400.
200-600

SETUP SERVO 18(22)

START CURRENT XXXX
ANTI-CLOCKWISEXXXX 18. Nominal value 240.
200-600

SETUP SERVO 19(22)

END CURRENT XXXX 19. Nominal value 400.
ANTI-CLOCKWISEXXXX
200-600
Continued on next page
 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE SETUP Group 20 P. 24

SETUP SERVO 20(22)

START VOLTAGE XXXX 20. Nominal value 65.
TILT XXXX
0-255

SETUP SERVO 21(22)

END VOLTAGE XXXX 21. Nominal value 175.
TILT XXXX
0-255

! Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE 80 Electronic overload protection Group 20 P. 25

CALIBRATION, Duplex boom

module 80 Electronic overload protection
Study the menu overviews under ECS, Terminal.
! Switch to the SERVICE menu with arrow RIGHT/LEFT

! Enter code 3. (The code is on the list from KALMAR)

Press ENTER.

CALIBR 80 1(16) 1. Boom in lowest position, i.e., minimum angle.

BOOM DOWN XXXX The display should show 100-200, which corresponds to 1-2
MINIMUM ANGLE XXXX V from the angle sensor. If the display shows more than 200
100-200 a red lamp lights. See adjustment of angle sensor.
0 on the display means a cable break - check.

CALIBR 80 2(16) 2. Raise the boom to its maximum angle. Check to ensure that
BOOM LIFT XXXX the figures on the display increase during the raising of the
MAX ANGLE XXXX
boom. When the boom is completely raised, press ENTER
to save the value.
If the figures decrease when the boom is being raised, the
connections on the angle sensor’s potentiometer may have
CALIBR 80 3(16) been reversed.
INNER BOOM XXXX
MIN XXXX
EXTENSION 3. Fully retract the boom.
Press ENTER to save the value.

CALIBR 80 4(16)
OUTER BOOM XXXX
MAX XXXX
EXTENSION 4. Fully extend the boom
Press ENTER to save the value.

CALIBR 80 5(16)
INNER BOOM
MIN EXTENSION 5. Fully retract the boom and lower to minimum angle.
LXXXX RXXXX F XXX.XX Press ENTER (X on line 1 becomes a filled rectangle) and
keep pressed down until the values for L and R are stable.
(L = left pressure sensor, R = right pressure sensor).
CALIBR 80 6(16) X
OUTER BOOM XXXX.0t
INIT BY MAX LOAD
LXXXX RXXXX F XXX.XX 6. Fully extend the boom, still at minimum angle.
Press ENTER (X on line 1 becomes a filled rectangle) until
the signals for L and R are reasonably stable. The value on
line 2 should be 0,0T for unloaded machines.
CALIBR 80 7(16)
DAMPING XXXXcm
END POSITION XXXX
7. End position damping. Example: A value of 40 gives 40 cm
damping distance for BOOM OUT/IN and a 4.0° damping
angle for LIFT/LOWER.

Continued on next page

 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE 80 Electronic overload protection Group 20 P. 26

8. Max. permitted height or min. permitted load centre. The

CALIBR 80 8(16) system disengages the LIFT/LOWER and BOOM OUT/IN
NOT USED functions at the registered max. height.

CALIBR 80 9(16)
LE= XXXX RI= XXXX 9. Not used.
XX.XXt L= XXXX
V=XXX.X

CALIBR 80 10(16) 10. Menus 10, 11 and 12 are regulator settings for vertical lift
REG BOOM P XXXX and are factory set by KALMAR.
XXXX (Nominal value 40)
LC-DISTANCE XXXX

CALIBR 80 11(16)
REG BOOM I XXXX 11. (Nominal value 10)
XXXX
LC-DISTANCE XXXX

CALIBR 80 12(16)
REG BOOM D XXXX
XXXX 12. (Nominal value 5)
LC-DISTANCE XXXX

CALIBR 80 13(16) 13. Help menu for the setting of menus 10, 11, 12.
P(XXXX+XXXX*I+
XXXX*D= XXXX
LC-DISTANCE XXXX

14. Nominal value 180. Limitation of lift speed. If the vertical lift
CALIBR 80 14(16) function does not function correctly, this may be due to the
LIMIT LIFT XXXX
SPEED XXXX flow of hydraulic fluid to the BOOM OUT function being insuf-
ficient. By registering a lower value on this menu, the flow to
the LIFT function is reduced, which results in a sufficient flow
to the BOOM OUT function.

CALIBR 80 15(16) 15. Nominal value 140. Limitation of lowering speed. See menu
LIMIT LOWER XXXX
SPEED XXXX 14 above.

! Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE 80 Electronic overload protection Group 20 P. 27

CALIBRATION, Triplex boom

module 80 Electronic overload protection
WARNING!
All calibration shall be carried out only
on the movements of the inner boom. Study the menu overviews under ECS, Terminal.
If both inner and intermediate booms are
fully extended there is a risk of tipping.

MAX MAX

MIN
MAX/MIN
OK

! Switch to the SERVICE menu with arrow RIGHT/LEFT

! Enter code 3. (The code is on the list from KALMAR)

Press ENTER.

1. Boom in lowest position, i.e., minimum angle.

The display should show 100-200, which corresponds to 1-2
CALIBR 80 1(16) V from the angle sensor. If the display shows more than 200
BOOM DOWN XXXX a red lamp lights. See adjustment of angle sensor.
MINIMUM ANGLE XXXX
100-200 0 on the display means a cable break - check.

2. Raise the boom to its maximum angle. Check to ensure that

the figures on the display increase during the raising of the
CALIBR 80 2(16)
BOOM UP XXXX boom. When the boom is completely raised, press ENTER
MAX ANGLE XXXX to save the value.
If the figures decrease when the boom is being raised, the
connections on the angle sensor’s potentiometer may have
been reversed.
CALIBR 80 3(16)
INNER BOOM XXXX 3. Fully retract the boom. Boom angle 5-10°.
MIN EXTENSION XXXX Press ENTER to save the value.
❒ MIDDLE BOOM +/-
❒ on the fourth line is used to switch between inner and outer
booms. Press +/-
❒ = Inner boom moves. ■ = Intermediate boom moves.
CALIBR 80 4(16)
OUTER BOOM XXXX 4. Fully extend the inner boom and fully retract the intermediate
MAX EXTENSION XXXX
❒ MIDDLE BOOM +/- boom. Boom angle 5-10°.
Press ENTER to save the value.
❒ on the fourth line is used to switch between inner and outer
booms. Press +/-
❒ = Inner boom moves. ■ = Intermediate boom moves..
Continued on next page
 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE 80 Electronic overload protection Group 20 P. 28

5. Fully retract the boom and lower to 5-10° angle.

Press ENTER (X on line 1 becomes a filled rectangle) and
CALIBR 80 5(16) X keep pressed down until the values for L and R are stable.
INNER BOOM (L = left pressure sensor, R = right pressure sensor).
INIT BY MIN LOAD
LXXXX RXXXX F XXX.XX
6. Fully extend the inner boom, still at 5-10° angle.
N.B. Intermediate boom MIN extension. See points 3 and 4.
CALIBR 80 6(16) Press ENTER (X on line 1 becomes a filled rectangle) until
OUTER BOOM XXXX.0t the signals for L and R are reasonably stable. The value on
INIT BY MAX LOAD line 2 should be 0,0T for unloaded machines.
LXXXX RXXXX F XXX.XX

7. End position damping. Example: A value of 40 gives 40 cm

CALIBR 80 7(16) damping distance for BOOM OUT/IN and a 4.0° damping
DAMPING XXXXcm angle for LIFT/LOWER.
END POSITION XXXX

8. Max. permitted height or min. permitted load centre. The

CALIBR 80 8(16) system disengages the LIFT/LOWER and BOOM OUT/IN
functions at the registered max. height.
NOT USED

9. Maximum permitted minimum load centre. The system dis-

CALIBR 60 9(16) engages the LIFT/LOWER and BOOM OUT/IN functions at
LE= XXXX RI= XXXX the registered load centre.
XX.XXT L= XXXX
V=XXX.X

CALIBR 80 10(16) 10. Menus 10, 11 and 12 are regulator settings for vertical lift
REG BOOM P XXXX and are factory set by KALMAR.
XXXX
LC-DISTANCE XXXX

CALIBR 80 11(16) 11.

REG BOOM I XXXX
XXXX
LC-DISTANCE XXXX

CALIBR 80 12(16)
REG BOOM D XXXX 12.
XXXX
LC-DISTANCE XXXX

CALIBR 80 13(16)
P(XXXX+XXXX*I+ 13. Help menu for the setting of menus 10, 11, 12.
XXXX*D= XXXX
LC-DISTANCE XXXX

14. Limitation of lift speed. If the vertical lift function does not
CALIBR 80 14(16) function correctly, this may be due to the flow of hydraulic flu-
LIMIT LIFT XXXX id to the BOOM OUT function being insufficient. By register-
SPEED XXXX ing a lower value on this menu, the flow to the LIFT function
is reduced, which results in a sufficient flow to the BOOM
OUT function.
CALIBR 80 15(16)
LIMIT LOWER XXXX 15. Limitation of lowering speed. See menu 14 above.
SPEED XXXX

! Press ENTER to return to the KALMAR INDUSTRIES

SERVICE main menu.
 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE Diagnosis Group 20 P. 29

Diagnosis
Study the menu overview under ECS, Terminal
! Switch to the KALMAR INDUSTRIES SERVICE menu using
arrow RIGHT (or LEFT).
Press ENTER

! Enter code 4.
(The code can be found on the list supplied by KALMAR)
Press ENTER

DIAG 1(8)
SPREADER LE X RI X 1. Checking the input signals to ECU for the SIDESHIFT LEFT
UNLOCK TW-L X and RIGHT, TWIST-LOCKS UNLOCKED and VERTICAL
VERT LIFT LIFT functions. If the signals are 24 V the X symbols then be-
come filled rectangles.

DIAG 2 (8)
LEVER 2. Checking the ECU input signals from the control lever.
X XX.XXV Y XX.XXV
Z XX.XXV

3. Checking of Module 80 sensors

LE = Left sensor, feed pressure in bar
DIAG 3(8) ANA IN RI = Right sensor, feed pressure in bar
LEXXXX RIXXXX RETXXX RET = Return pressure in bar
ANGLE XX.XXV
LENGTH XX.XXV ANGLE = Voltage from angle sensor
LENGTH = Voltage from length sensor.
Check to make sure that the values change when the ma-
chine is being operated.

DIAG 4(8) DIG IN 4. Signals from sensors on the top lift.

TW ULOC X OVERR X
TW LOCK X DRIV OKX
ALIGNM X
Continued on next page
When the signals are 24V, the X symbols become filled rec-
tangles.
S TW OP = Sensor for twist-locks unlocked
S TW LO = Sensor for twist-locks locked
OVERR = By passing of the safety system
ALIGN = Sensor for alignment
DRIV OK = OK for normal operation:
– the cab is in its rear position
– if the cab is in the forward position, doors closed
– with remote control - contact OK
– dead man’s grip OK
– twist-locks either LOCKED or UNLOCKED
– no front overload, no steered axle overload
 0014
ContChamp DRD100-200 ECU 5 00-08
ECS SERVICE Diagnosis Group 20 P. 30

DIAG 5(8) ANA OUT 5.

UP/DOWN XXXXmA
IN/OUT XX.XXV
ROTXXXXmA TILTXX.XXV

DIAG 6(8) 6.
NUMBER OF CONTAINER
LIFTS
XXXXXXXXX

7. This menu is used to check that the machine is working ac-

ALLOWED LOAD XXX.XXt cording to the actual load curve.
LOAD XXX.XXt The highest permissible rear load (steered axele load) is 34
LOAD STR AXLEXXX.XXt
LC-DISTANCEXXX.XXm or 44 tonnes, depending on model.
Operate the attachment to a number of positions and check
that the front and rear load is less than the permitted load,
thus the machine is operating below the load curve.

Load
c
b

a
LC-distance from drive
axle centre

a = Permitted working area

b = The overload protection system interrupts the hydraulic functions
c = Load curve

DIAG 8(8) 8. Press ENTER to return to the KALMAR INDUSTRIES

RETURN TO MAIN MENU SERVICE main menu.

ENTER