Kalmar Montacargas DCE 90-180, DCE 70-32E3-70-35E Workshop Manual (PDF - Io)

64 D Error codes – 1 Engine
Description Limitation Action
SPN/FMI CID/EID
656/2 6/2 This diagnostic code is applicable to The engine will be derated while this di- *
six cylinder engines only. agnostic code is active.
ECU794 detects the following condi-
tion:
• Data from the electronic unit injec-
tor for the No. 6 cylinder is out of
limits.
• Diagnostic code 168-1 is not ac-
tive.
• Diagnostic codes 651-5 and 651-6
are not active.
• No 678 diagnostic codes are ac-
tive.
tive.
tive.
tive.
656/5 6/5 This diagnostic code is applicable to The engine will have low power and/or *
six cylinder engines only. rough running.
This diagnostic code is designed to in-
dicate an open circuit (low current) in
either the solenoid or the wiring for the
electronic unit injector for No. 6 cylin-
der.
tions:
• A low current condition (open cir-
cuit) for each of five consecutive
attempts to operate.
• Battery voltage is higher than 9
volts for 2 seconds.
VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

D Error codes – 1 Engine 65
SPN/FMI CID/EID
656/6 6/6 This diagnostic code is applicable to The engine will have low power and/or *
six cylinder engines only rough running.
This diagnostic code is designed to in-
dicate a short circuit (high current) in
either the solenoid or the wiring for the
electronic unit injector for No. 6 cylin-
der.
tions:
• A high current condition (short cir-
cuit) for each of five consecutive
attempts to operate.
• Battery voltage above 9 volts for 2
seconds.
656/7 6/7 This diagnostic code is applicable to The engine will be derated. *
six cylinder engines only.
The electronic unit injector is no longer
capable of delivering the correct
amount of fuel.
676/5 2246/5 Glow plug start aid relay, current low. The engine may be difficult to start in *
cold temperatures and the exhaust may
emit white smoke.
676/6 2246/6 ECU794 has detected a high current The engine may be difficult to start in *
condition ( short circuit) after attempt- cold temperatures and the exhaust may
ing to activate the glow plug starting emit white smoke.
aid
tions:
• The engine is not cranking.
• ECU794 has been powered for at
least one second.
• There is a high current condition
(short circuit) for more than two
seconds.
678/3 41/3 ECU794 detects the following condi- The engine may be limited to low idle. *
tions: Note: The 8 volt supply may provide
• The 8 volt supply is more than 8.8 power to the digital throttle position sen-
VDC for more than one second. sor.
• ECU794 has been powered for Note: The 8 volt supply provides power
more than three seconds. to the two speed/timing sensors.
Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

SPN/FMI CID/EID
678/4 41/4 ECU794 detects the following condi- The engine may be limited to low idle. *
tions: Note: The 8 volt supply may provide
• The 8 volt supply is less than 7.2 power to the digital throttle position sen-
VDC for more than one second. sor.
• ECU794 has been powered for Note: The 8 volt supply provides power
more than three seconds. to the two speed/timing sensors.
tive.
723/8 342/8 ECU794 detects the following condi- The performance will not be affected un- *
tions: less both speed signals are lost. The
• The signal from the secondary loss of the signals from both speed/tim-
speed/timing sensor is lost and/or ing will cause ECU794 to shut down the
intermittent. engine. The engine will not restart if the
signal from the secondary speed/timing
• The signal from the secondary sensor is lost.
speed/timing sensor was lost for at
least 2 seconds while the signal
from the primary speed/timing
sensor remained valid and the en-
gine was running.
tive.
• The engine has been running for
more than 3 seconds.
tive.
1079/3 262/3 ECU794 detects the following condi- The engine will be derated. *
tions:
• The 5 volt supply is greater than
5.16 VDC for more than one sec-
ond.
least three seconds.
tive.

D Error codes – 1 Engine 67
SPN/FMI CID/EID
1079/4 262/4 ECU794 detects the following condi- The engine will be derated. *
tions:
• The 5 volt supply is less than 4.84
VDC for more than one second.
least three seconds.
tive.
1188/7 526/7 This diagnostic code indicates that the The engine may not reach top rpm. *
intake manifold pressure is not being The engine produces excessive black
controlled correctly. smoke.
ECU794 detects the following condi- The engine has low power.
tions:
• ECU794 has been powered for
more than 4 seconds.
• Diagnostic code 168 is not active.
tive.
• Diagnostic codes 646-5 and 646-6
are not active.
1347/5 1779/5 This diagnostic code indicates that An electrical fault may prevent the provi- *
ECU794 has detected an open circuit sion of pressure to the fuel rail. This may
or low current condition in the solenoid result in the loss of fuel injection. If the
for the fuel rail. solenoid for the fuel rail pump fails, it is
likely that fuel will not be pumped into the
fuel rail. The engine will stop or the en-
gine will not start.
1347/6 1779/6 This diagnostic code indicates that An electrical fault may prevent the provi- *
ECU794 has detected a short circuit or sion of pressure to the fuel rail. This may
high current condition in the solenoid result in the loss of fuel injection. If the
for the fuel rail. solenoid for the fuel rail pump fails, it is
1347/7 1779/7 Fuel rail pump, Not responding. An electrical fault may prevent the provi- *
sion of pressure to the fuel rail. This may
result in the loss of fuel injection. If the
solenoid for the fuel rail pump fails, it is

SPN/FMI CID/EID
2789/15 194/1 ECU794 monitors the following param- Engine power is reduced *
eters in order to estimate the exhaust
temperature:
• Intake manifold air temperature
• Barometric pressure
• Engine speed
High intake manifold air temperature,
high altitude operation and high engine
loads can cause the exhaust tempera-
ture to increase to a level that may
damage the components of the ex-
haust system. When this occurs,
ECU794 derates the engine in order to
reduce the exhaust temperature. This
protects the components of the ex-
haust system from damage.
*) See component supplier documentation.

D Error codes – 2 Transmission 69
2 Transmission
mm mm mm mm mm mm
Error codes transmission alternative

page
–
Dana TE13000 and TE17000

In case of serious transmission malfunctions the control unit uses two
modes with reduced functionality to protect the transmission against
damage, Limp-home mode and Shut-down mode.
For more detailed description see section 2 Transmission, group 2.8
Control system transmission.
Code
00/50 Memory error in control unit Transmission locked in neu- -
transmission. tral (shutdown).



20/60 Sensor oil pressure (B253) Transmission locked in neu- Check cabling between control unit and com-
indicates low oil pressure tral (shutdown). ponent.
when there should be pres- Check the solenoid valve.
sure.
20/61 The oil pressure sensor Transmission locked in neu- Check cabling between control unit and com-
(B253) indicates oil pressure tral (shutdown). ponent.
when there should not be Check the solenoid valve.
pressure.
21/02 Solenoid valves VFS short- Transmission locked in neu- Check cabling between the control unit and
circuiting to voltage, ground, tral (shutdown). the component with diagnostic menu.
or open circuit. Check the solenoid valve.
30/04 Low battery voltage. Control unit saves stored in- Check cabling to control unit.
formation to flash memory Check alternator, battery and cabling be-
and restarts to clear memory. tween battery and alternator.
30/05 High battery voltage. Control unit receives re- Check voltage feed.
duced proportional control If auxiliary start equipment is connected, dis-
precision depending on re- connect it.
duced PWM work cycle.
31/00 Reference voltage sensor 8 Control unit receives re- Check voltage feed.
V, too low. duced sensor signals. Check the control unit.

70 D Error codes – 2 Transmission
Code
31/01 Reference voltage sensor 8 Control unit receives re- Check voltage feed.
V, too high. duced sensor signals. Check the control unit.
40/06 Incorrect direction from gear Control unit locks transmis- Check cabling to gear selector with regards to
selector. sion in neutral. forward and reverse signal.
41/06 Incorrect gear selection from Control unit doesn’t allow Check cabling to gear selector with regards to
gear selector. change of range, however, signal range.
operation of machine is pos-
sible.
42/04 Actual gear ratio too low. Control unit indicates that Check transmission with purpose to under-
one or several clutches are stand if and, if that is the case, which clutch is
slipping. slipping.
Check the set gear ratio for the control unit.
42/05 Actual gear ratio too high. Control unit indicates that Check transmission with purpose to under-
one or several clutches are stand if and, if that is the case, which clutch is
slipping. slipping.
Check the set gear ratio for the control unit.
43/03 Signal from Sensor engine Control unit indicates the er- Check cabling between control unit and com-
rpm and oil temperature ror. ponent.
transmission (B758/766) out- Check the sensor.
side valid interval.
43/07 Torque converter tempera- Control unit indicates the er- Check transmission oil cooler, clean as need-
ture exceeds 100 C. ror to make operator aware ed.
of the warning’s level. Check the thermostat in the transmission oil
cooler.
43/08 Torque converter tempera- The control unit protects the Check transmission oil cooler, clean as need-
ture exceeds 125 C. transmission and does not al- ed.
low the temperature in the Check the thermostat in the transmission oil
torque converter to exceed cooler.
the limit value.
The control unit locks the
transmission in neutral posi-
tion, the engine is restricted
to 50% of max. rpm.
44/10 Faulty signal for accelerator - Use diagnostic menu to find incorrect seg-
pedal position from engine ment.
control unit (D794)
46/05 Max. torque for inching has - -

been exceeded.

Code
50/00 Sensor oil pressure (B253), Transmission in limp-home. Check cabling between control unit and com-
short-circuited to ground. ponent.
Check the sensor.
50/01 Sensor oil pressure (B253), Transmission in limp-home. Check cabling between control unit and com-
not connected or open cir- ponent.
cuit. Check the sensor.
51/00 Sensor engine rpm and oil The control unit limits the Check cabling between control unit and com-
temperature transmission transmission’s temperature ponent.
(B758/766) short-circuited to measurement to the lowest Check the sensor.
ground. value in its settings, which re-
sults in poor temperature
compensation.
51/01 Sensor engine rpm and oil The control unit limits the Check cabling between control unit and com-
temperature transmission transmission’s temperature ponent.
(B758/766) not connected or measurement to the highest Check the sensor.
open circuit. value in its settings, which re-
compensation.
52/00 Sensor oil temperature The control unit limits the Check cabling between control unit and com-
(S221) short-circuited to transmission’s temperature ponent.
ground. measurement to the highest Check the sensor.
value in its settings, which re-
compensation.
52/01 Sensor oil temperature The control unit limits the Check cabling between control unit and com-
(S221) open circuit. transmission’s temperature ponent.
measurement to the highest Check the sensor.
value in its settings, which re-
compensation.
54/00 Reference voltage sensor 5 - Check cabling between control unit and com-
V short-circuiting to frame ponent.
ground. Check the sensor.
54/01 Reference voltage sensor 5 - Check cabling between control unit and com-
V open circuit. ponent.
Check the sensor.

Code
60/00 Sensor rpm drum (B752) When only one rpm signal Check cable between control unit and com-
short-circuited to ground. that is not the engine rpm sig- ponent.
nal is incorrect, the control Check component.
unit calculates the missing
rpm.
If several rpm signals or if the
engine rpm signal are defec-
tive, the control unit activates
Limp-home.
60/01 Sensor rpm drum (B752) not When only one rpm signal Check cable between control unit and com-
connected. that is not the engine rpm sig- ponent.
rpm.
Limp-home.
61/00 Sensor rpm output shaft When only one rpm signal Check cable between control unit and com-
(B758) short-circuited to that is not the engine rpm sig- ponent.
ground. nal is incorrect, the control Check component.
rpm.
Limp-home.
61/01 Sensor rpm output shaft When only one rpm signal Check cable between control unit and com-
(B758) not connected. that is not the engine rpm sig- ponent.
rpm.
Limp-home.

Code
62/00 Sensor engine rpm (B758/ When only one rpm signal Check cable between control unit and com-
766), short-circuited to that is not the engine rpm sig- ponent.
ground. nal is incorrect, the control Check component.
rpm.
Limp-home.
62/01 Sensor engine rpm (B758/ When only one rpm signal Check cable between control unit and com-
766), not connected or has that is not the engine rpm sig- ponent.
open circuit. nal is incorrect, the control Check component.
rpm.
Limp-home.
63/00 Sensor rpm turbine (B751) When only one rpm signal Check cable between control unit and com-
short-circuited to ground. that is not the engine rpm sig- ponent.
rpm.
Limp-home.
63/01 Sensor rpm turbine (B751) When only one rpm signal Check cable between control unit and com-
not connected. that is not the engine rpm sig- ponent.
rpm.
Limp-home.
70/00 Solenoid valve VFS front Transmission in limp-home. Check cabling between control unit and com-
(Y630), short-circuited to ponent.
each other, signal cable Check the solenoid valve.
short-circuited to voltage, or
plus-cable short-circuited to
frame ground.

Code
70/01 Solenoid valve VFS forward Transmission in limp-home. Check cabling between control unit and com-
(Y630) open circuit or short- ponent.
circuited voltage. Check the solenoid valve.
(Y630), control current high- ponent.
er than 1400 mA. Check the solenoid valve.
(Y630), control current out- ponent.
side approved interval. Incor- Check the solenoid valve.
rect impedance.
71/00 Solenoid valve VFS 2/4 Transmission in limp-home. Check cabling between control unit and com-
(Y6069), short-circuited to ponent.
each other, signal cable Check the solenoid valve.
short-circuited to voltage, or
plus-cable short-circuited to
frame ground.
(Y6069), control current ponent.
higher than 1400 mA. Check the solenoid valve.
side approved interval (incor- Check the solenoid valve.
rect impedance).
72/00 Solenoid valve VFS reverse Transmission in limp-home. Check cabling between control unit and com-
(Y631), cables short- ponent.
circuited to each other, signal Check the solenoid valve.
cable short-circuited to volt-
age, or plus-cable short-
circuited to frame ground.
(Y631), control current high- ponent.
er than 1400 mA. Check the solenoid valve.

Code
rect impedance).
(Y6067), cables short- ponent.
circuited to each other, signal Check the solenoid valve.
cable short-circuited to volt-
age, or plus-cable short-
(Y6067), control current ponent.
higher than 1400 mA. Check the solenoid valve.
rect impedance).
77/02 All gear packs disengaged. Transmission locked in neu- -

tral (shutdown).
80/00 Solenoid valve RSP Drive Transmission locked in neu- Check cabling between control unit and com-
(Y6066), cable short- tral (shutdown). ponent.
circuited to frame ground. Check the solenoid valve.
80/01 Solenoid valve RSP Drive Transmission locked in neu- Check cabling between control unit and com-
(Y6066), cable is not con- tral (shutdown). ponent.
nected or short-circuited to Check the solenoid valve.
voltage.
81/00 Solenoid valve VFS 2/4 Transmission in limp-home. Check cabling between control unit and
(Y6074), cable short- component.
81/01 Solenoid valve VSF 2/4 Transmission in limp-home. Check cabling between control unit and com-
(Y6074), cable is not con- ponent.
voltage.
82/00 Solenoid valve VFS 1/3 Transmission in limp-home. Check cabling between control unit and
(Y6075), cable short- component.

Code
82/01 Solenoid valve VSF 1/3 Transmission in limp-home. Check cabling between control unit and
(Y6075), cable is not con- component.
voltage.
83/00 Solenoid valve RSP Drive Transmission locked in neu- Check cabling to solenoid valve drive
(Y6066), cable short- tral (shutdown). Check solenoid valve drive.
83/01 Solenoid valve RSP Drive Transmission locked in neu- Check cabling to solenoid valve drive
(Y6066), cable is not con- tral (shutdown). Check solenoid valve drive.
nected or short-circuited to
voltage.
90/xx - 99/ System error. Transmission locked in neu- -

xx tral (shutdown).
95/71 Control unit cannot interpret - -

input data.
99/90 Incorrect software in control - -

unit transmission.

Error codes transmission alternative

–
ZF 3WG161
For serious transmission errors, the control unit uses four modes with
reduced functionality to protect the transmission from damage. These
are:
• “Substitute clutch control”.
In this state the driver can use the machine as normal. However,
gear shifting and change of travel direction does not take place
under the control of normal modulation. The control unit uses
standard values for modulating clutches.
• “Limp home”.
In this state the driver can use one of the transmission gears in
each direction, and in some cases only in one direction. To con-
tinue driving with a fault and the limitation “Limp home” active, the
machine must be stopped, coming to a standstill, the gear selector
moved to neutral before a gear can be selected again.
• “Transmission shut down”.
In this state the transmission is permanently in neutral as the so-
lenoid valves for the clutches and parts of the power supply to the
transmission are shutoff. Park the machine and switch off the en-
gine.
• “TCU shut down”.
In this state the transmission is permanently in neutral as all the
solenoid valves and all power supplies to the transmission are
shutoff. Park the machine and switch off the engine.
SPN/FMI ZF code
(hex)
5000/12 11 Logical error at gear range signal. Transmission locked Check the cables from ECU793 to
ECU793 detected a wrong signal in neutral (“transmis- shift lever.
combination for the gear range. sion shut down”). Check signal combinations of shift
Possible reasons: lever positions for gear range.
• Cable from shift lever to

ECU793 is broken.
• Cable is defective and is con-
tacted to battery voltage or ve-
hicle ground.
• Shift lever is defective.

SPN/FMI ZF code
(hex)
5010/12 12 Logical error at direction select sig- Transmission locked Check the cables from ECU793 to
nal. in neutral (“transmis- shift lever.
ECU793 detected a wrong signal sion shut down”). Check signal combinations of shift
combination for the direction. lever positions F-N-R.
Possible reasons:
• Cable from shift lever to
ECU793 is broken.
hicle ground.
5020/12 13 Logical error at engine derating de- After selecting neu- Restart ECU 793 by switching the
vice. tral, ECU793 chang- ignition on and off.
TCU detected no reaction of en- es to “limp home”. Check engine derating device.
gine while derating device activ.
5040/12 15 Logical error at direction select sig- Transmission locked Check the cables from ECU793 to
nal 2. shift lever. in neutral (“transmis- shift lever 2.
ECU793 detected a wrong signal sion shut down”) Check signal combinations of shift
combination for the direction when extra direction lever positions F-N-R.
selector is used.
Possible reasons:
• Cable from shift lever 2 to
ECU793 is broken
hicle ground.
5050/12 16 LOGICAL ERROR AT AXLE CON- - Check the cable from ECU793 to
NECTION feedback axle connection switch.
Feedback axle connection meas- Check signals of the feedback con-
ured by ECU793 and output signal nection switch.
axle connection don't fit.
Possible reasons:
• Axle can’t be connected or dis-
connected due to mechanical
problem
• one of the cables from feed-
back axle connection switch to
ECU793 is broken.

SPN/FMI ZF code
(hex)
5110/3 25 S.C. to battery voltage or O.C. at ECU793 uses de- Check the cable from ECU793 to
transmission sump temperature fault temperature. the sensor.
sensor input. Check the connectors.
The measured voltage is too high. Check the temperature sensor.
Possible reasons:
tacted to battery voltage.
• Cable has no connection to
ECU793.
• Temperature sensor has an
internal defect.
• Connector pin is contacted to
battery voltage or is broken.
5110/4 26 S.C. to ground at transmission ECU793 uses de- Check the cable from ECU793 to
sump temperature sensor input. fault temperature. the sensor.
The measured voltage is too low. Check the connectors.
Possible reasons: Check the temperature sensor.
tacted to vehicle ground.
internal defect.
vehicle ground.
retarder/torque converter tempera- fault temperature. the sensor.
ture sensor input. Check the connectors.
The measured voltage is too high. Check the temperature sensor.
Possible reasons:
ECU793.
internal defect.

SPN/FMI ZF code
(hex)
5120/4 28 S.C. to ground at retarder/torque ECU793 uses de- Check the cable from ECU793 to
converter temperature sensor in- fault temperature. the sensor.
put Check the connectors.
The measured voltage is too low. Check the temperature sensor.
Possible reasons:
• cable is defective and is con-
• temperature sensor has an in-
ternal defect.
• connector pin is contacted to
vehicle ground.
parking brake sensor input. fault value. the sensor.
The measured voltage is too high. Check the connectors.
Possible reasons: Check the parking brake sensor.
ECU793.
• Sensor has an internal defect.
5130/4 2A S.C. to ground parking brake sen- ECU793 uses de- Check the cable from ECU793 to
sor input. fault value. the sensor.
Possible reasons: Check the parking brake sensor.
vehicle ground.

SPN/FMI ZF code
(hex)
5135/3 2C Short circuit to battery voltage or ECU793 uses de- Check the cable from ECU793 to
open circuit in DLM TRACTION fault value. the sensor.
ADJUST DASHBOARD DEVICE Check the connectors.
INPUT.
Check the DLM Traction Adjust
The measured voltage is too high. dashboard device.
Possible reasons:
1. Cable is defective and is con-
2. Cable has no connection to
ECU793.
3. Sensor has an internal defect.
4. Connector pin is contacted to
5135/4 2D S.C. to ground DLM traction adjust ECU793 uses de- Check the cable from ECU793 to
dashboard device input. fault value. the sensor.
Possible reasons: Check the DLM Traction Adjust
• Cable is defective and is con- dashboard device.
• Sensor has an internal defect
vehicle ground.
5137/3 2E S.C. to battery voltage or O.C. at ECU793 uses de- Check the cable from ECU793 to
DLM steering angle sensor input. fault value. the sensor.
The measured voltage is too high. Check the connectors.
Possible reasons: Check the DLM steering angle sen-
• Cable is defective and is con- sor.
ECU793.

SPN/FMI ZF code
(hex)
5137/4 2F S.C. to ground DLM steering angle ECU793 uses de- Check the cable from ECU793 to
sensor input. fault value. the sensor.
Possible reasons: Check the DLM steering angle sen-
• Cable is defective and is con- sor.
vehicle ground.
5313/12 2B Inchsensor-signal mismatch. During inching Check the cable from ECU793 to
The measured voltage from CCO mode: ECU793 the sensor.
and CCO2 signal don’t match. shifts to neutral. Check the connectors.
Possible reasons: While not inching: no Check the sensor.
change
• Cable is defective.
5140/3 31 S.C. to battery voltage or O.C. at Transmission limited Check the cable from ECU793 to
engine speed input. according to “Substi- the sensor.
ECU793 measures a voltage high- tute clutch control”. Check the connectors.
er than 7.00 V at speed input pin. Check the speed sensor.
Possible reasons:
ECU793.
• Speed sensor has an internal
defect.
battery voltage or has no con-
tact.

SPN/FMI ZF code
(hex)
5140/4 32 S.C. to ground at engine speed in- Transmission limited Check the cable from ECU793 to
put. according to “Substi- the sensor.
ECU793 measures a voltage less tute clutch control”. Check the connectors.
than 0.45V at speed input pin. Check the speed sensor.
Possible reasons:
• Cable / connector is defective
and is contacted to vehicle
ground.
defect.
5140/12 33 Logical error at engine speed in- Transmission limited Check the cable from ECU793 to
ECU793 measures a engine tute clutch control”. Check the connectors.
speed over a threshold and the Check the speed sensor.
next moment the measured speed
Check the sensor gap.
is zero.
Restart ECU 793 by switching the
Possible reasons:
ignition on and off.
and has bad contact.
defect.
• Sensor gap has the wrong
size.
turbine speed input. according to “Substi- the sensor.
ECU793 measures a voltage high- tute clutch control”, Check the connectors.
er than 7.00 V at speed input pin. on output tachome-
Check the speed sensor.
ter sensor error, the
Possible reasons: transmission control
• Cable is defective and is con- unit activates “limp
tacted to battery voltage. home”.
ECU793.
defect.
tact.

SPN/FMI ZF code
(hex)
5150/4 35 S.C. to ground at turbine speed in- Transmission limited Check the cable from ECU793 to
ECU793 measures a voltage less tute clutch control”, Check the connectors.
than 0.45V at speed input pin. on output tachome-
ter sensor error, the
• Cable / connector is defective unit activates “limp
and is contacted to vehicle home”.
ground.
defect.
5150/12 36 Logical error att turbine speed in- Transmission limited Check the cable from ECU793 to
ECU793 measures a turbine tute clutch control”, Check the connectors.
speed over a threshold and at the on output tachome-
next moment the measured speed ter sensor error, the
transmission control Check the sensor gap.
is zero.
unit activates “limp Restart ECU 793 by switching the
Possible reasons: home”. ignition on and off.
and has bad contact
defect.
size.
internal speed input. according to “Substi- the sensor.
ECU793 measures a voltage high- tute clutch control”. Check the connectors.
er than 7.00 V at speed input pin. Check the speed sensor.
Possible reasons:
ECU793.
defect.
tact.

SPN/FMI ZF code
(hex)
5160/4 38 S.C. to ground at internal speed in- Transmission limited Check the cable from ECU793 to
ECU793 measures a voltage less tute clutch control”. Check the connectors.
than 0.45V at speed input pin. Check the speed sensor.
Possible reasons:
and is contacted to vehicle
ground.
defect.
5160/12 39 Logical error at internal speed in- Transmission limited Check the cable from ECU793 to
ECU793 measures a internal tute clutch control”. Check the connectors.
speed over a threshold and at the Check the speed sensor.
next moment the measured speed
Check the sensor gap.
is zero.
Restart ECU 793 by switching the
Possible reasons:
ignition on and off.
1. Cable / connector is defective
2. Speed sensor has an internal
defect.
3. Sensor gap has the wrong
size.
5170/3 3A S.C. to battery voltage or O.C. at Transmission limited Check the cable from ECU793 to
output speed input. according to “Substi- the sensor.
ECU793 measures a voltage high- tute clutch control”, Check the connectors.
er than 12.5 V at speed input pin. on turbine speed
sensor error, the
• Cable is defective and is con- unit activates “limp
tacted to battery voltage. home”.
ECU793.
defect.
tact.

SPN/FMI ZF code
(hex)
5170/4 3B S.C. to ground at output speed in- Transmission limited Check the cable from ECU793 to
ECU793 measures a voltage less tute clutch control”, Check the connectors.
than 1.00V at speed input pin. on turbine speed
sensor error, the
• Cable / connector is defective unit activates “limp
and is contacted to vehicle home”.
ground.
defect.
5170/12 3C Logical error at output speed input. Transmission limited Check the cable from ECU793 to
ECU793 measures a output speed according to “Substi- the sensor.
over a threshold and at the next tute clutch control”, Check the connectors.
moment the measured speed is on turbine speed
zero. sensor error, the
transmission control Check the sensor gap.
Possible reasons: unit activates “limp Restart ECU 793 by switching the
• Cable / connector is defective home”. ignition on and off.
defect.
size.
5180/2 3E Output speed zero doesn’t fit to Transmission limited Check the sensor signal of output
other speed signals. according to “Substi- speed sensor.
If transmission is not neutral and tute clutch control”, Check the sensor gap of output
the shifting has finished, ECU793 on turbine speed speed sensor.
measures outputspeed zero and sensor error, the
Check the cable from ECU793 to
turbine speed or internal speed not transmission control
the sensor.
equal to zero. unit activates “limp
home”.. Restart ECU 793 by switching the
Possible reasons: ignition on and off.
defect.
size.

SPN/FMI ZF code
(hex)
5260/9 54 DCT1 timeout Check display computer.
Timeout of CAN-message DCT1 Check wire of CAN-Bus.
from display computer. Check cable to display computer.
Possible reasons:
• Interference on CAN-Bus.
• CAN wire/connector is broken.
• CAN wire/connector is defec-
tive and has contact to vehicle
ground or battery voltage.
5270/9 E5 DISPID1_timeout ECU793 select pa- Check display controller.

Timeout of CAN-message rameter set with ID0. Check wire of CAN-Bus.
DISPID1 from display controller. Control unit trans- Check cable to display controller.
Possible reasons: mission activates
“limp home”.
1. Interference on CAN-Bus.
2. CAN wire/connector is broken.
3. CAN wire/connector is defec-
tive and has contact to vehicle
ground or battery voltage.
5390/2 61 AEB Request signal. Last selection is Check I/O controller.

CAN signal for AEB request is de- kept. Check wire of CAN-Bus.
fective. Check cable to I/O controller.
Possible reasons:
• I/O controller is defective.
• Interference on CAN-Bus.
5480/3 71 S.C. to battery voltage at clutch Control unit trans- Check the cable from ECU793 to
K1. mission activates the gearbox.
The measured resistance value of “limp home”. With an Check the connectors from
the valve is out of limit, the voltage ongoing error on an- ECU793 to the gearbox.
at K1 valve is too high. other gear, the trans-
Check the regulator resistance.
mission control unit
Possible reasons: Check internal wire harness of the
activates “TCU shut-
• Cable / connector is defective down”. gearbox.
and has contact to battery volt-
age.
• Regulator has an internal de-
fect.

SPN/FMI ZF code
(hex)
5480/4 72 S.C. to ground at clutch K1. Control unit trans- Check the cable from ECU793 to
The measured resistance value of mission activates the gearbox.
the valve is out of limit, the voltage “limp home”. With an Check the connectors from
at K1 valve is too low. ongoing error on an- ECU793 to the gearbox.
other gear, the trans-
Possible reasons: Check the regulator resistance.
• Cable / connector is defective activates “TCU shut- Check internal wire harness of the
and has contact to vehicle down”. gearbox.
ground.
and has contact to another
regulator output of the
ECU793.
fect.
5480/5 73 O.C. at clutch K1 Control unit trans- Check the cable from ECU793 to
the valve is out of limit. “limp home”. With an Check the connectors from
ongoing error on an- ECU793 to the gearbox.
Possible reasons: other gear, the trans-
• Cable / connector is defective Check the regulator resistance.
and has no contact to activates “TCU shut- Check internal wire harness of the
ECU793. down”. gearbox.
fect.
age.
fect.

SPN/FMI ZF code
(hex)
ground.
ECU793.
fect.
fect.
age.
fect.

SPN/FMI ZF code
(hex)
ground.
ECU793.
fect.
fect.
age.
fect.

SPN/FMI ZF code
(hex)
ground.
ECU793.
fect.
5510/5 83 O.C. at clutch K4. Control unit trans- Check the cable from ECU793 to
fect.
KV, forward clutch. mission activates the gearbox.
at KV valve is too high. other gear, the trans-
age.
fect.

SPN/FMI ZF code
(hex)
5520/4 85 S.C. to ground at clutch KV, for- Control unit trans- Check the cable from ECU793 to
ward clutch. mission activates the gearbox.
at KV valve is too low. other gear, the trans-
and has contact to vehicle
ground.
ECU793.
fect.
5520/5 86 O.C. at clutch KV, forward clutch. Control unit trans- Check the cable from ECU793 to
fect.
KR, reverse clutch. mission activates the gearbox.
at KR valve is too high. other gear, the trans-
mission control unit Check the regulator resistance.
age.
fect.

SPN/FMI ZF code
(hex)
5530/4 88 S.C. to ground at clutch KR, re- Control unit trans- Check the cable from ECU793 to
verse clutch. mission activates the gearbox.
at KR valve is too low. other gear, the trans-
and has contact to vehicle
ground.
ECU793.
fect.
5530/5 89 O.C. at clutch KR, reverse clutch Control unit trans- Check the cable from ECU793 to
fect.
5535/3 8B S.C. to battery voltage at DLM - Check the cable from ECU793 to
transversal output. the valve.
ECU793 detected a wrong voltage Check the connectors from
at the output pin, that looks like a ECU793 to the gearbox.
s.c. to battery voltage. Check the resistance of valve.
Possible seasons:
• Device has an internal defect.
battery voltage.

SPN/FMI ZF code
(hex)
5535/4 8A S.C. to ground at DLM transversal Output will be on until Check the cable from ECU793 to
output. ECU793 power the valve.
ECU793 detected a wrong voltage down even if error Check the connectors from
at the output pin, that looks like a vanishes (loose con- ECU793 to the gearbox.
s.c. to vehicle ground. nection).
Check the resistance of valve.
Possible reasons:
vehicle.
5536/3 8E S.C. to battery voltage at DLM indi- - Check the cable from ECU793 to
cator lamp output. the device.
s.c. to battery voltage. Check the resistance of device.
Possible reasons:
battery voltage.
5536/5 8F O.C. DLM indicator lamp output. - Check the cable from ECU793 to
ECU793 detected a wrong voltage the device.
at the output pin, that looks like a Check the connectors from
o.c. for this output pin. ECU793 to the gearbox.
Possible reasons: Check the resistance of device.
• Cable is defective and has no
connection to ECU793.
• Connector has no connection
to ECU793.

SPN/FMI ZF code
(hex)
5545/3 D8 S.C. to battery voltage at DLM lon- - Check the cable from ECU793 to
gitudinal output. the valve.
s.c. to battery voltage. Check the resistance of valve.
Possible reasons:
battery voltage.
5545/4 D7 S.C. to ground at DLM longitudinal Output will be on until Check the cable from ECU793 to
output. ECU793 power the valve.
ECU793 detected a wrong voltage down even if error Check the connectors from
at the output pin, that looks like a vanishes (loose con- ECU793 to the gearbox.
s.c. to vehicle ground. nection).
Check the resistance of valve.
Possible reasons:
vehicle ground.
5560/5 93 O.C. at relay reverse warning - Check the cable from ECU793 to
alarm. the backup alarm device.
ECU793 detected a wrong voltage Check the connectors from backup
at the output pin, that looks like a alarm device to ECU793.
o.c. for this output pin. Check the resistance of backup
Possible reasons: alarm device.
• Cable is defective and has no
• Backup alarm device has an
internal defect.
to ECU793.

SPN/FMI ZF code
(hex)
5570/3 95 S.C. to battery voltage at relay - Check the cable from ECU793 to
starter interlock. the starter interlock relay.
ECU793 detected a wrong voltage Check the connectors from starter
at the output pin, that looks like a interlock relay to ECU793.
s.c. to battery voltage. Check the resistance of starter in-
Possible reasons: terlock relay.
• Starter interlock relay has an
internal defect.
battery voltage.
5570/4 94 S.C. to ground at relay starter in- - Check the cable from ECU793 to
terlock. the starter interlock relay.
ECU793 detected a wrong voltage Check the connectors from starter
at the output pin, that looks like a interlock relay to ECU793.
s.c. to vehicle ground. Check the resistance of starter in-
Possible reasons: terlock relay.
internal defect.
vehicle ground.
5570/5 96 O.C. at relay starter interlock. - Check the cable from ECU793 to
ECU793 detected a wrong voltage the starter interlock relay.
at the output pin, that looks like a Check the connectors from starter
o.c. for this output pin. interlock relay to ECU793.
Possible reasons: Check the resistance of starter in-
• Cable is defective and has no terlock relay.
internal defect.
to ECU793.

SPN/FMI ZF code
(hex)
5620/3 A6 S.C. to battery voltage at warning - Check the cable from ECU793 to
signal output. the warning device.
ECU793 detected a wrong voltage Check the connectors from warning
at the output pin, that looks like a device to ECU793.
s.c. to battery voltage. Check the resistance of warning de-
Possible reasons: vice.
• Warning device has an inter-
nal defect.
battery voltage.
5620/4 A4 S.C. to ground at warning signal - Check the cable from ECU793 to
output. the warning device.
ECU793 detected a wrong voltage Check the connectors from warning
at the output pin, that looks like a device to ECU793.
s.c. to vehicle ground. Check the resistance of warning de-
Possible reasons: vice.
nal defect.
vehicle ground.
5620/5 A5 O.C. at warning signal output. - Check the cable from ECU793 to
ECU793 detected a wrong voltage the warning device.
at the output pin, that looks like a Check the connectors from warning
o.c. for this output pin. device to ECU793.
Possible reasons: Check the resistance of warning de-
• Cable is defective and has no vice.
nal defect.
to ECU793.

SPN/FMI ZF code
(hex)
5660/2 B1 Slippage at clutch K1. Control unit trans- Check pressure at clutch K1.
ECU793 calculates a differential mission activates Check main pressure in the system.
speed at closed clutch K1. If this “limp home”. With an
Check sensor gap at internal speed
calculated value is out of range, ongoing error on an-
sensor.
ECU793 interprets this as slipping other gear, the trans-
mission control unit Check sensor gap at output speed
clutch.
activates “TCU shut- sensor.
Possible reasons: down”. Check signal at internal speed sen-
• Low pressure at clutch K1. sor.
• Low main pressure. Check signal at output speed sen-
• Wrong signal at internal speed sor.
sensor. Replace clutch.
• Wrong signal at output speed
sensor.
• Wrong size of the sensor gap.
• Clutch is defective.
sensor.
clutch.
sensor.

SPN/FMI ZF code
(hex)
sensor.
clutch.
sensor.
sensor.
clutch.
• Wrong signal at turbine speed
sensor.

SPN/FMI ZF code
(hex)
5680/2 B5 Slippage at clutch KV, forward Control unit trans- Check pressure at clutch KV.
clutch. mission activates Check main pressure in the system.
ECU793 calculates a differential “limp home”. With an
speed at closed clutch KV. If this ongoing error on an-
sensor.
calculated value is out of range, other gear, the trans-
ECU793 interprets this as slipping
clutch.
down”. Check signal at internal speed sen-
Possible reasons:
sor.
• Low pressure at clutch KV.
Check signal at output speed sen-
• Low main pressure. sor.
• Wrong signal at internal speed Replace clutch.
sensor.
sensor.
5685/2 B6 Slippage at clutch KR, reverse Control unit trans- Check pressure at clutch KR.
clutch. mission activates Check main pressure in the system.
ECU793 calculates a differential “limp home”. With an
speed at closed clutch KR. If this ongoing error on an-
sensor.
calculated value is out of range, other gear, the trans-
ECU793 interprets this as slipping
clutch.
down”. Check signal at internal speed sen-
Possible reasons:
sor.
• Low pressure at clutch KR.
Check signal at output speed sen-
• Low main pressure. sor.
• Wrong signal at internal speed Replace clutch.
sensor.
sensor.
5700/0 B7 Overtemp sump. - Cool down machine.

ECU793 measured a temperature Check oil level.
in the oil sump that is over the al- Check temperature sensor.
lowed threshold.

SPN/FMI ZF code
(hex)
5730/0 BA Differential oil pressure filter. - Check oil filter.
ECU793 measured a voltage at Check wiring from ECU793 to dif-
differential pressure switch out of ferential pressure switch.
the allowed range. Check differential pressure switch
Possible reasons: (measure resistance) which should
• Oil filter is contaminated. be around 510 Ohms normally and
open circuit when contaminated fil-
• Cable/connector is broken or ter.
cable/connector is contacted
to battery voltage or vehicle
ground.
• Differential pressure switch is
defective.
5745/15 BC Overspeed output. -

ECU793 messures an transmis-
sion output speed above the de-
fined threshold.
5751/0 C0 Engine torque or engine power -

overload.
ECU793 calculates an engine
torque or engine power above the
defined thresholds.
5752/0 C1 Transmission output torque over- -

load.
ECU793 calculates an transmis-
sion output torque above the de-
fined threshold.
5755/15 C2 Transmission input torque over- Programmable: No VARNING!

load reaction or shift to
ECU793 calculates an transmis- neautral.
sion input torque above the de-
fined threshold.
5760/0 C3 Overtemp converter output. - Cool down machine.

ECU793 measured a oil tempera- Check oil level.
ture at the converter ouput that is Check temperature sensor.
over the allowed threshold.

SPN/FMI ZF code
(hex)
5770/3 C4 S.C. to ground at joystick status in- - Check the cable from ECU793 to
dicator. joystick status indicator.
ECU793 detected a wrong voltage Check the connectors from joystick
at the output pin, that looks like a status indicator to ECU793.
s.c. to vehicle ground. Check the resistance of joystick sta-
Possible reasons: tus indicator.
• Joystick status indicator has
an internal defect.
vehicle ground.
5770/4 C5 S.C. to battery voltage at joystick - Check the cable from ECU793 to
status indicator. joystick status indicator.
ECU793 detected a wrong voltage Check the connectors from joystick
at the output pin, that looks like a status indicator to ECU793.
s.c. to battery voltage. Check the resistance of joystick sta-
Possible reasons: tus indicator.
an internal defect.
battery voltage.
5770/5 C6 O.C. at joystick status indicator. - Check the cable from ECU793 to
ECU793 detected a wrong voltage joystick status indicator.
at the output pin, that looks like a Check the connectors from joystick
o.c. for this output pin. status indicator to ECU793.
Possible reasons: Check the resistance of joystick sta-
• Cable is defective and has no tus indicator.
an internal defect.
to ECU793.

SPN/FMI ZF code
(hex)
5810/3 D1 S.C. to battery voltage at power See error codes no. Check cables and connectors to
supply for sensors. 25 to 2C. sensors, which are supplied from
ECU793 measures more than 6V AU1
at the pin AU1 (5V sensor supply). Check the power supply at the pin
AU1 (should be appx. 5V).
Error codes no. 25 to no. 2C may be
a reaction of this fault.
5810/4 D2 S.C. to ground at power supply for See error codes no. Check cables and connectors to
sensors. 25 to 2C. sensors, which are supplied from
ECU793 measures less than 4V at AU1
the pin AU1 (5V sensor supply). Check the power supply at the pin
AU1 (should be appx. 5V).
Error codes no. 25 to no. 2C may be
a reaction of this fault.
5820/3 D4 High voltage at battery. Transmission con- Check power supply battery.
Measured voltage at power supply trol unit activates Check cables from batteries to
is higher than: “TCU shutdown” ECU793.
• 18 V (12V device) Check connectors from batteries to
• 32.5 V (24V device). ECU793.
5820/4 D3 Low voltage at battery Transmission con- Check power supply battery.
measured voltage at power supply trol unit activates Check cables from batteries to
is lower than: “TCU shutdown” ECU793.
• 10 V (12V device) Check connectors from batteries to
• 18 V (24V device). ECU793.

SPN/FMI ZF code
(hex)
5830/2 D5 Error at value power supply VPS1. Transmission con- Check fuse.
ECU793 switched on VPS1 and trol unit activates Check cables from gearbox to
measured VPS1 is off or ECU793 “TCU shutdown”. ECU793.
switched off VPS1 and measured Check connectors from gearbox to
VPS1 is still on. TECU793.
Possible reasons: Replace ECU793.
• Cable or connectors are de-
fect and are contacted to bat-
tery voltage.
fect and are contacted to vehi-
cle ground.
• Permanent power supply
KL30 missing.
• ECU793 has an internal de-
fect.
5840/2 D6 Error valve power supply VPS2. Transmission con- Check fuse.
ECU793 switched on VPS2 and trol unit activates Check cables from gearbox to
measured VPS2 is off or ECU793 “TCU shutdown”. ECU793.
switched off VPS2 and measured Check connectors from gearbox to
VPS2 is still on. ECU793.
Possible reasons: Replace ECU793.
fect and are contacted to bat-
tery voltage.
fect and are contacted to vehi-
cle ground.
• Permanent power supply
KL30 missing.
• ECU793 has an internal de-
fect.

SPN/FMI ZF code
(hex)
5860/3 E3 S.C. to battery voltage at display - Check the cable from ECU793 to
output. the display.
ECU793 sends data to the display Check the connectors at the dis-
and measures allways a high volt- play.
age level on the connector. Change display.
Possible reasons:
fective and are contacted to
battery voltage.
• Display has an internal defect.
5860/4 E4 S.C. to ground at display output. - Check the cable from ECU793 to
ECU793 sends data to the display the display.
and measures allways a high volt- Check the connectors at the dis-
age level on the connector. play.
Possible reasons: Change display.
fective and are contacted to
vehicle ground.
• Display has an internal defect.
5880/2 E6 Illegal ID request via CAN. Transmission in neu-

tral. Transmission
control unit activates
“TCU shutdown”.
5890/2 F1 General EEPROM fault. - Replace ECU793.

ECU793 can't read non volantile Often shown together with error
memory. code F2.
Possible reason:
• ECU793 is defective.
5900/13 F2 Configuration lost. Transmission con- Reprogramm the correct configura-

ECU793 has lost the correct control unit activates tion for the machine (e.g. with clus-
figuration and can't control the “TCU shutdown”. ter controller,...).
transmission.
Possible reasons:
• Interference during saving
data on non volatile memory.
• ECU793 is brand new or from
another vehicle.

SPN/FMI ZF code
(hex)
5910/13 F3 Application error. Transmission con- Replace ECU793.
Something of this application is trol unit activates This fault occurs only if an test engi-
wrong. “TCU shutdown”. neer did something wrong in the ap-
plication of the machine.
5930/7 F5 Clutch failure. Transmission con- ECU793 shows also the affected
AEB was not able to adjust clutch trol unit activates clutch on the Display.
filling parameters. “TCU shutdown”.
Possible reason:
• One of the AEB-Values is out
of limit.
5930/13 F6 Clutch adjustment data lost or in- Default values = 0 for Execute AEB.
chpedal calibration data lost. AEB offsets used.
ECU793 was not able to read cor- No Inchmode availa-
rect clutch adjustment parameters. ble.
Possible reason:
• Interference during saving
data on non volatile memory.
• ECU793 is brand new.

D Error codes – 8 Control system 107
8 Control system
mm mm mm mm mm mm
Error codes machine

page
–
Code Description Limitation Action
1 Time for service interval has been ex- Make maintenance according to
ceeded. service schedule.
Activate new service interval with
service interval code.
10 Communication fault ECU 790. Operation not possible. Check the power supply to the ECU
790. Check the CAN bus for breaks.
11 Communication, defective cable Operation not possible. Check the cable between ECU 790
ECU 790 - EDU 795. and EDU 795.
Short-circuit or open circuit.
12 Communication fault ECU 793. Check the cable between ECU 793
Short-circuit or open circuit. and EDU 795.
13 Communication fault ECU 794. Check the cable between ECU 794
Short-circuit or open circuit. and EDU 795.
14 Communication ECU 796, not re- Check the power supply to the ECU
sponding. 796. Check the CAN bus for breaks.
15 Communication, defective cable Check cable.

ECU 795 - ECU 796.
16 Communication, defective cable Check cable.

ECU 796 - ECU 790.
17 Memory error, check sum EDU 795. Operation not possible. Re-start ECU 795. Load programs. If
Display not in function. that does not help, replace ECU 795.
18 Communication ECU 792, not re- Check the power supply to the ECU
sponding. 792. Check the CAN bus for breaks.
301 Voltage supply error ECU 790. Reduction of engine speed. Check fuse according to manual.
Supply voltage below 14 or above 33 Measure battery voltage or check
V for 5 s. acid level.
303 Reference voltage error, 5V, ECU Reduction of engine speed. Measure 5 V reference. Possible
790. sensor fault or short-circuit to battery
Reference voltage below 4,5 or minus.
above 5,5 V for 50 ms.
304 Defective sensor for electric scales. Possible cable open circuit. Check
Signal below 0.20V for 5s. cable from chassi to mast.

108 D Error codes – 8 Control system
305 Defective speed sensor. Reduction of engine speed. Investigate fitting of sensor and cable
Machine speed above 40 km/h for to it. Search for open circuit or open
one second or too fast change of conductor. Important that the dis-
speed (2 km/h at 20ms). tance between sensor and cam disc
is correct, contact Kalmar Industries.
Measure output signal with oscillo-
scope.
306 Defective engine rev sensor. Reduction of engine speed. Check that the sensor is properly
Engine speed above 3500 rpm for 1s screwed in the flywheel cover so that
or too fast change of speed (150 rpm correct distance to the ring gear is ob-
at 20 ms). tained. On the front edge of the sen-
sor is a flange which must rest
against the flywheel cover. Also
check the cable to the sensor if there
is open circuit or open conductors.
Measure output signal with oscillo-
scope.
307 Defective gear selector. Reduction of engine speed. Check for physical damage or cable
Logical fault or unexpected input from open circuit.
lever.
320 Defective sensor for hydrostatic drive Reduction of engine speed. Check connector on pressure sensor
pressure (forward). mounted on hydraulic pump.
Signal below 0.20V or above
4.80V for 2s.
321 Defective sensor for hydrostatic drive Reduction of engine speed. Check connector on pressure sensor
pressure (reverse). mounted on hydraulic pump.
4.80V for 2s.
322 Defective hydraulic pressure sensor Engine speed does not increase Check connector on pressure sen-
for lift lever. when using lift lever. sor.
4.80V for 2s.
323 Short-circuit or open circuit on output Reduction of engine speed. Measure the valve’s resistance. Must
signal EDC valve pump (forward). not be under 15 Ohm. Check with
data sheet from valve manufacturer.
signal EDC valve pump (reverse). not be under 15 Ohm. Check with
signal PDC valve hydraulic motor. not be under 15 Ohm. Check with

350 Battery voltage low. Check the alternator and the charg-
Battery voltage below 23 V if engine ing circuit. Measure acid level and if
is running for 12 s. needed charge battery. If that doesn't
help replace battery/batteries
351 Battery voltage high. Check the alternator’s 24V output.

Battery voltage above 30 V for 10 s. Check cabling.
352 Fuel level low. Activity can be continued. Fill with fuel.
Less than 15 % for 40 s.
353 Defective sensor fuel level. Activity can be continued. Check the sensor’s resistance. It
should be between 0 and 73 Ohm.
354 Coolant level low. Reduction of engine speed. Fill with refrigerant.
Low level for 40 s.
355 Hydraulic oil temperature high. Do not use hydraulic functions before
Hydraulic oil temperature over the temperature has fallen below
100 °C for 40 seconds. 70 °C. Hydraulic fluid may catch fire if
above 100 °C.
356 Defective sensor hydraulic oil tem- Activity can be continued. Check sensor resistance. It should
perature. be 8.5 kohm at 0 °C and 290 ohm at
If value above 138 °C or below - 100 °C.
30 °C.
357 Brake system, accumulator pressure Reduction of engine speed. Stop machine. Check accumulator.
low.
Brake pressure low for 10s. The pres-
sure can be low for 60s at start-up.
370 Engine particulate filter. Time to re- Regenerate particulate filter in 30

generate particulate filter in 30 min- minutes.
utes.
371 Engine particle filter. Time to regen- Reduction of engine speed. Regenerate particulate filter.
erate.
372 High pressure in the particulate filter. Reduction of engine speed. Regenerate particulate filter.
Pressure high for 1 minute.
380 Defective accelerator LF (Left Front). Reduction of engine speed. Check cable and physical installation
Accelerator pedal signal below 0,2 V of pedal. Calibrate pedal.
or above 4,8 V or 0,3 V out of calibrat-
ed values for 500 ms.
381 Defective accelerator RF (Right Reduction of engine speed. Check cable and physical installation
Front). of pedal. Calibrate pedal.
Accelerator pedal signal below 0,2 V

382 Defective accelerator LR (Left Rear). Reduction of engine speed. Check cable and physical installation
Accelerator pedal signal below 0,2 V of pedal. Calibrate pedal.
383 Defective accelerator RR (Right Reduction of engine speed. Check cable and physical installation
Rear). of pedal. Calibrate pedal.
Accelerator pedal signal below 0,2 V
384 Defective servo motor for injector Reduction of engine speed. Check cable and physical installation
pump engine. of servo motor. Calibrate servo.
Servo feedback above 4,8 V or 0,5 V
out of calibrated values for 500 ms or
too fast change of feedback.
390 Defective valve to variable pump for Measure the valve’s resistance.
Optimum Speed/Optimum Rev, short Should not be under 10 Ohm. Check
circuit or open circuit at terminal with data sheet from valve manufac-
K2:28. turer.
400 Fault in sensor for reversible driver’s Only driving with operator’s seat Measure the signal with a multimeter
seat. in forward direction is possible. or use the built-in diagnostic system
Sensor faulty or open circuit in signal in the KCS to check whether the sig-
wire. Signal below 0,3V or above nal is within the permissible limits.
4,7V for 200ms. Mechanical sensor Use the diagnostic menus (KCS,
fault. monitoring) to investigate K1:37.
401 Overload lift and tilt according to cali- Speed limitation. Put down and lift lighter loads.
brate table.
Machine capacity exceeded.
402 Parking brake error. Parking brake doesn’t release. Check parking brake pressure after
Parking brake valve or parking brake valve. Check parking brake switch.
switch out of order.
404 Coolant level sensor error. Check cable from sensor and make
Signal from sensor below 0.2V or sure coolant level is ok.
above 4.8V.
405 Seat turning sensing logic error. Possible to turn seat but with limi- Check cables and connections to
Signal from sensor below 0.2V or tations. seat sensing logic.
above 4.8V.
406 Tiltaxle force sensor error. Overload protection disabled. Overload protection is disabled. Do
Sensor signal below 0.1V or above not overload machine. Replace sen-
4.8V for 10s. sor.
601 Voltage supply error, ECU 796. Measure battery voltage. Check fuse
Supply voltage below 14 or above 58-4 no. 6 (5 A).
33 V.

602 Memory error, check sum ECU 796. Re-start ECU 796. Load program. If
that does not help, replace ECU 796.
603 Reference voltage 10V error, ECU Measure 10V reference between
796. X46.7 (0 V) and X46.6 (10V).
Reference voltage below 9 or above
11 V for 50 ms.
604 Voltage supply error PWM outputs, Hydraulics not working. Switch off the hydraulic functions.
ECU 796. Check if emergency stop is de-
Supply voltage below 14 or above 33 pressed at the electrical servo.
V for 5s. Measure battery voltage. Check fuse
58-4 no. 7 (10 A).
605 Communication error XA-PWM, K2. Hydraulic functions not working. Re-start ECU 796. If that does not
help, replace ECU 796.
606 Communication error XA-PWM, K3. Hydraulic functions not working. Re-start ECU 796. If that does not
help, replace ECU 796.
610 Error, input signal from lever for hy- Hydraulic function 1 not working. Check the potentiometer fitting and
draulic function 1. cable. The signal voltage should be
Signal from sensor below 0.6 V or between 0-10 V.
above 9.4 V for 100 ms.
615 Short-circuit or open circuit for main Hydraulic function 1 not working. Measure the valve’s resistance. Must
valve hydraulic function 1A at termi- not be under 15 Ohm. Check with
nal K2:3. data sheet from valve manufacturer.
valve hydraulic function 1B at termi- not be under 15 Ohm. Check with

626 Defective sensor for vertical align- Vertical alignment not working. Switch off vertical alignment.
ment. Check the potentiometer fitting and
Signal below 0,5V or above 9,5V for cable.
100ms.
627 Defective sensor for pre-selected lift- Pre-selected lifting height not Switch off pre-selected lifting height.
ing height. working.
Signal below 0,5V or above 9,5V for
100ms.
628 CTX communication error. Clamping Only manual clamping function is CTX clamping controller inoperative.
control no reply. possible. Select manual clamping control.
Check cable to clamping controller.
630 Fault in pressure sensor P1 for auto- Clamping pressure is estimated to Check the cable for the pressure sen-
matic clamping unit. be the set value. WARNING! sor on the clamping unit.
Signal below 0.5V or above 10.5V for There is no automatic increase in Check the pressure sensor.
2s. clamping pressure.
631 Fault in pressure sensor P2 for auto- Clamping pressure is estimated to Check the cable for the pressure sen-
matic clamping unit be the set value. WARNING! sor on the clamping unit.

632 Short circuit or open circuit in hydrau- Clamping prevented. Measure the valve resistance. This
lic valve at terminal K3:3. should not be less than 15 Ohm. Use
the manufacturer’s data sheet to
check. Check the cable connected to
the valve.
633 Short circuit or open circuit in clamp- Clamping prevented. Measure the valve resistance. This
ing pressure valve, on/off. should not be less than 15 Ohm. Use
the valve.
634 Short circuit or open circuit in valve Not possible to shut off left side. Measure the valve resistance. This
for left clamping arm, on/off. should not be less than 15 Ohm. Use
the valve.
635 Short circuit or open circuit in valve Not possible to shut off right side. Measure the valve resistance. This
for right clamping arm, on/off. should not be less than 15 Ohm. Use
the valve.
636 Short circuit or open circuit in upper Not possible to shut off upper left Measure the valve resistance. This
left clamping arm valve on/off. side. should not be less than 15 Ohm. Use
the valve.
637 Short circuit or open circuit in middle Not possible to shut off middle Measure the valve resistance. This
right clamping arm valve on/off. right side. should not be less than 15 Ohm. Use
the valve.
638 Short circuit or open circuit in middle Not possible to shut off middle left Measure the valve resistance. This
left clamping arm valve on/off. side. should not be less than 15 Ohm. Use
the valve.
639 Short circuit or open circuit in upper Not possible to shut off upper right Measure the valve resistance. This
right clamping arm valve on/off. side. should not be less than 15 Ohm. Use
the valve.
642 Fault in pressure sensor for opening Clamping prevented. Check the cable for the pressure sen-
clamping unit. sor for opening the clamping unit.
Signal below 0.5V or above 10.5V for Check the pressure sensor.
2s.

643 Fault in pressure sensor for closing Clamping prevented. Check the cable for the pressure sen-
clamping unit. sor for closing the clamping unit.
Signal below 0.5V or above 10.5V for Check the pressure sensor.
2s.
644 Switch for selecting left or right Not possible to shut off left or right Check the switch.
clamping unit. side. Check the cable connected to the
switch.
645 Overload Speed reduction to max 1 km/h.
646 Short circuit or open circuit in upper Clamping on left side not possi- Measure the valve resistance. This
left bypass valve on clamp. ble. should not be less than 15 Ohm. Use
the valve.
647 Short circuit or open circuit in middle Clamping on left side not possi- Measure the valve resistance. This
left bypass valve on clamp. ble. should not be less than 15 Ohm. Use
the valve.
648 Short circuit or open circuit in left se- Clamping on left side not possi- Measure the valve resistance. This
quence valve on clamp. ble. should not be less than 15 Ohm. Use
the valve.
650 Short circuit or open circuit in upper Clamping on right side not possi- Measure the valve resistance. This
right bypass valve on clamp. ble. should not be less than 15 Ohm. Use
the valve.
651 Short circuit or open circuit in middle Clamping on right side not possi- Measure the valve resistance. This
right bypass valve on clamp. ble. should not be less than 15 Ohm. Use
the valve.
652 Short circuit or open circuit in right se- Clamping on right side not possi- Measure the valve resistance. This
quence valve on clamp. ble. should not be less than 15 Ohm. Use
the valve.
654 Pressure sensor P3 left long arm Clamping on left side not possi- Check the cable for the pressure sen-
fault, paper clamp. ble. sor for P3 left long arm.
Check the pressure sensor.
655 Pressure sensor P3 left short arm Clamping on left side not possi- Check the cable for the pressure sen-
fault, paper clamp. ble. sor for P3 left short arm.

656 Pressure sensor P3 right long arm Clamping on right side not possi- Check the cable for the pressure sen-
fault, paper clamp. ble. sor for P3 right long arm.
657 Pressure sensor P3 right short arm Clamping on right side not possi- Check the cable for the pressure sen-
fault, paper clamp. ble. sor for P3 right short arm.
658 Pressure select switch fault. Clamp pressure one is selected. Check switch mounting and cable.
Signal voltage should be between
0.2-9.8 V.
659 Pressure sensor P1 on left arm fault, Clamping pressure is estimated to Check the cable for the pressure sen-
paper clamp. be the set value. WARNING! sor.
660 Pressure sensor P2 on left arm fault, Clamping pressure is estimated to Check the cable for the pressure sen-
paper clamp. be the set value. WARNING! sor.
Signal below 0.5 V or above There is no automatic increase in Check the pressure sensor.
10.5 V for two seconds. clamping pressure.
661 Pressure sensor P1 on right arm Clamping pressure is estimated to Check the cable for the pressure sen-
fault, paper clamp. be the set value. WARNING! sor.
662 Pressure sensor P2 on right arm Clamping pressure is estimated to Check the cable for the pressure sen-
fault, paper clamp. be the set value. WARNING! sor.
900 Fault code from gearbox control unit. Depending on type of fault. See Error codes transmission alter-
SPN and FMI code is shown if avail- native Dana TE13000 and TE17000
able. page 69.
See Error codes transmission alter-
native ZF 3WG161 page 77.
1200 Error code from engine control unit. Depending on type of fault. See Error codes engine alternative
SPN and FMI code is shown if avail- Volvo TAD650VE, TAD660VE,
able. TAD750VE and TAD760VE page 10.
See Error codes engine alternative
Cummins QSB6.7 page 21.
See Error codes engine alternative
Caterpillar C6.6 page 39.

1501 Defective sensor for feedback steer- Steering turns off automatically. Check potentiometer and cabling
ing. from the steer sensor. The signal
Signal below 0,3 V or above 4,7 V for should be between 0.5 and 4.5V.
100ms or mechanical sensor fault.
1502 Defective steer lever. Steering turns off automatically. Check potentiometer and cabling
Signal below 0,3 V or above 4,7 V for from the steer lever. The signal
100ms or mechanical sensor fault. should be between 0.5 and 4.5V.
1503 Defective mini steering 2-channel po- Steering turns off automatically. Check cabling. Measure potentiome-
tentiometer. ter channels 1 and 2 (oscilloscope re-
Unexpected input from potentiome- quired).
ter. Signal value below 0,2V or above
4,8V
1504 Short-circuit or open circuit on output Steering turns off automatically. Measure the valve’s resistance. Must
signal for right steering valve. not be under 15 Ohm. Check with
1505 Short-circuit or open circuit on output Steering turns off automatically. Measure the valve’s resistance. Must
signal for left steering valve. not be under 15 Ohm. Check with
1506 Voltage supply error, ECU 792. Reduction of engine speed. Check fuse according to manual.
Supply voltage below 14 or above Measure battery voltage or check
33 V for 5s. acid level.
1507 Reference voltage 5V error, ECU Reduction of engine speed. Measure 5 V reference. Possible
792. sensor fault or short-circuit to battery
Reference voltage below 4,5 or minus.
above 5,5 V for 50 ms.

D Error codes – 9 Frame, body, cab and accessories 117
9 Frame, body, cab and

mm mm mm mm mm mm
accessories
9.4 Heating, ventilation and air
conditioning
ECC: Reading out error code
page
–
NOTE
In case of an error code, perform the recommended actions ac-
cording to the error code table to find the problem.
If there is a fault in any sensor, or if the pressure monitor has tripped,
A B C
“ERROR” will be flashed on the display.
Keep the auto button (position E) depressed for a few seconds to show
the current fault(s) as text on the display.
Scroll between error messages, using the temperature buttons (posi-
tions A and B). The selected error message is indicated with an arrow
on the display.
AUTO
MODE
The fault cause is indicated with a left arrow (position F).
003708
The pressure monitor is re-set with the button for reducing fan speed
(position C). Keep the button depressed for several seconds to reset.
E F
A. Scrolling between error messages Return by briefly pressing the auto button (position E).
B. Scrolling between error messages

C. Resetting the pressure monitor
D. -
E. Auto mode
F. Fault cause

118 D Error codes – 9.4 Heating, ventilation and air conditioning
ECC: Error code table

–
Error Description Limitation Recommended action
Heatervalve The heater valve has failed or be- Pin 10 should have a volt- Check wiring harness.
Open come disconnected. age of approx. 5 V all the Is the heater valve connected?
time.
Heatervalve The heater valve has been shorted to Change heater valve.
Short ground. Pin 9 should have a volt-
age of approx. 0.9 V
Heatervalve Is the heater valve stuck? when fully closed and ap-
Stuck prox. 2.7 V when fully
open.
Pin 8 should have ground
potential all the time.
Pin 6, when valve is clos-
ing voltage should be ap-
prox. 12 V, when opening
approx. 0 V, when
stopped approx. 0 V.
Pin 5, when valve is clos-
ing voltage should be ap-
prox. 0 V, when opening
approx. 12 V, when
stopped approx. 0 V.
Inside sensor The connection between ECC and Resistance should be ap- Check wiring harness.
Open sensor has been broken. prox. 10 kohm at 25 °C. Sensor connected?
Inside sensor The connection between ECC and Measure resistance.
Short sensor has been shorted to ground.
Replace sensor.
Outside sensor The connection between ECC and Resistance should be ap- Check wiring harness.
Outside sensor The connection between ECC and Measure resistance.
Replace sensor.
Deicing sensor The connection between ECC and Resistance should be ap- Check wiring harness.
Deicing sensor The connection between ECC and Measure resistance.
Replace sensor.
Aftercoil sensor The connection between ECC and Resistance should be ap- Check wiring harness.
Aftercoil sensor The connection between ECC and Measure resistance.
Replace sensor.

D Error codes – 9.4 Heating, ventilation and air conditioning 119
Error Description Limitation Recommended action
AC system fail- There is a problem with the ECC sys- Control refrigerant charge.
ure tem. Either over pressure or not Control pressure switch.
enough refrigerant. System can be
Refrigerant leakage?
reset. Shutdown, restart and from the
error menu the fan down key resets
the error.

120 D Error codes – 9.4 Heating, ventilation and air conditioning

E Schematics 1
E Schematics
Table of Contents E Schematics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram A40750.1800 ............................................................................ 4
Hydraulic diagram A40750.2100 .......................................................................... 10
11 Common electrics ........................................................................................ 16
Circuit diagram, description ................................................................................. 16
Component designations ...................................................................................... 18
Circuit diagrams, compilation ............................................................................... 19

2 E Schematics

E Schematics – 10 Common hydraulics 3
10 Common hydraulics
mm mm mm mm mm mm
Hydraulic diagrams, compilation

page
–
Designation, drawing no., reference Functions included
Hydraulic diagram A40750.1800 page 4 Brake, steering, load handling (hydraulic servo) and pumps
Hydraulic diagram A40750.1900 page 6 Brake, steering, load handling (container) and pumps
Hydraulic diagram A40750.2000 page 8 Brake, steering, load handling (electrical servo) and pumps
Hydraulic diagram A40750.2100 page 10 Brake, mini-wheel/lever steering, load handling (hydraulic servo) and pumps
Hydraulic diagram A40750.2200 page 12 Brake, mini-wheel/lever steering, load handling (electrical servo) and pumps
Hydraulic diagram A40750.3000 page 14 Brake, mini-wheel/lever steering, load handling (joy-stick) and pumps

4 E Schematics – 10 Common hydraulics
Hydraulic diagram A40750.1800

page
–
20
19
22 20
21
22
18
17
23
24
14
15
25
26
12
13
16
27 28 29
30
11
9
10
8
6
7
1
2
5
3
008359 (A40750.1800 ver.1

4
2
32
33
34
31
1

1. Wheel brake 18. Control levers

2. Brake cylinder 19. Load control valve
3. Drive axle block 20. Lift cylinder
4. Hydraulic oil cooler 21. Load holding valve
5. Parking brake calliper 22. Tilt cylinder
6. Switch normally closed (NC) disengagement (S220) 23. Flow divider
7. Switch normally open (NO) brake light (S216) 24. Side shift and spreading cylinders
8. Shuttle valve, reversible operator’s seat 25. Levelling cylinder
9. Brake valve 26. Breather filter hydraulic oil tank
10. Switch normally closed (NC) low brake pressure (S204) 27. Hydraulic oil pump for brake system and servo circuit for
11. Extra brake valve, reversible operator’s seat load handling
12. Accumulator 28. Hydraulic oil pump for steering and load handling
13. Main valve 29. Hydraulic oil pump for lifting and tilting
14. Switch normally open (NO) parking brake (S200) 30. High-pressure filter
15. Solenoid valve parking brake (Y642) 31. Steering valve
16. Control valves for levelling, spreading and side shift 32. Directional valve with solenoid valve steering forward
(Y636-1) and steering reverse (Y636-2), reversible driver´s
17. Control valves for tilt and lift seat
33. Steering cylinder
34. Hydraulic oil tank


page
–
22
20
21
22
23
24
18
24
17
25
19
14
15
26
28
27
12
13
16
29 30 31
32
11
9
10
8
6
7
1
2
5
3
008360 (A40750.1900 ver.1

4
2
34
35
36
33
1

1. Wheel brake 19. Solenoid valve blocking lift (Y6045)

2. Brake cylinder 20. Solenoid valve blocking twistlock (Y6044)
3. Drive axle block 21. Load control valve
4. Hydraulic oil cooler 22. Lift cylinder
5. Parking brake calliper 23. Load holding valve
6. Switch normally closed (NC) disengagement (S220) 24. Tilt cylinder
7. Switch normally open (NO) brake light (S216) 25. Side shift cylinder
8. Shuttle valve, reversible operator’s seat 26. Spreading cylinders
9. Brake valve 27. Twistlock cylinders
10. Switch normally closed (NC) low brake pressure (S204) 28. Breather filter hydraulic oil tank
11. Extra brake valve, reversible operator’s seat 29. Hydraulic oil pump for brake system and servo circuit for
12. Accumulator load handling
13. Main valve 30. Hydraulic oil pump for steering and load handling
14. Switch normally open (NO) parking brake (S200) 31. Hydraulic oil pump for lifting and tilting
15. Solenoid valve parking brake (Y642) 32. High-pressure filter
16. Control valves for twistlock, spreading and side shift 33. Steering valve
17. Control valves for tilt and lift 34. Directional valve with solenoid valve steering forward
18. Control levers seat


page
–
24
23
26 24
25
22
21
26
27
28
20
14
15
29
30
12
13
19 18
17
31 32 33
16
34
11
9
10
8
6
7
1
2
5
3
008361 (A40750.2000 ver.1

4
2
36
37
38
35
1

1. Wheel brake 21. Solenoid valve lift (Y6005) or lower (Y6004)

2. Brake cylinder 22. Solenoid valve tilt in (Y6011) or out (Y6010)
3. Drive axle block 23. Load control valve
4. Hydraulic oil cooler 24. Lift cylinder
5. Parking brake calliper 25. Load holding valve
6. Switch normally closed (NC) disengagement (S220) 26. Tilt cylinder
7. Switch normally open (NO) brake light (S216) 27. Flow divider
8. Shuttle valve, reversible operator’s seat 28. Side shift and spreading cylinders
9. Brake valve 29. Levelling cylinder
10. Switch normally closed (NC) low brake pressure (S204) 30. Breather filter hydraulic oil tank
13. Main valve 32. Hydraulic oil pump for steering and load handling
14. Switch normally open (NO) parking brake (S200) 33. Hydraulic oil pump for lifting and tilting
15. Solenoid valve parking brake (Y642) 34. High-pressure filter
16. Control valves for levelling, spreading and side shift 35. Steering valve
17. Solenoid valve levelling down (Y6022) or up (Y6023) 36. Directional valve with solenoid valve steering forward
18. Solenoid valve spreading in (Y6019) or out (Y6018) seat
19. Solenoid valve side shift left (Y6020) or out (Y6021) 37. Steering cylinder
20. Control valves for tilt and lift 38. Hydraulic oil tank


page
–
20
19
22 20
21
22
18
17
23
24
14
15
25
26
12
13
16
27 28
29
11
9
10
31
8
29
30
6
33
1
2
5
3
008362 (A40750.2100 ver.1

4
32
2
35
36
37
34
1

1. Wheel brake 18. Control levers

10. Switch normally closed (NC) low brake pressure (S204) 27. Hydraulic oil pump for steering and load handling
11. Extra brake valve, reversible operator’s seat 28. Hydraulic oil pump for lifting and tilting
12. Accumulator 29. High-pressure filter
13. Main valve 30. Hydraulic oil pump mini-wheel/lever steering
14. Switch normally open (NO) parking brake (S200) 31. Hydraulic oil pump for brake system and servo circuit for
15. Solenoid valve parking brake (Y642) load handling
16. Control valves for levelling, spreading and side shift 32. Control valve mini-wheel/lever steering
17. Control valves for tilt and lift 33. Solenoid valve steering right (Y615-1) and left (Y615-2)
34. Steering valve
35. Directional valve with solenoid valve steering forward
seat


page
–
24
23
26 24
25
22
21
26
27
28
20
14
15
29
30
12
13
19 18
17
31 32
33
16
11
9
10
35
8
33
34
6
37
1
2
5
3
008363 (A40750.2200 ver.1

4
2
36
39
40
41
38
1

1. Wheel brake 22. Solenoid valve tilt in (Y6011) or out (Y6010)

10. Switch normally closed (NC) low brake pressure (S204) 31. Hydraulic oil pump for steering and load handling
11. Extra brake valve, reversible operator’s seat 32. Hydraulic oil pump for lifting and tilting
12. Accumulator 33. High-pressure filter
13. Main valve 34. Hydraulic oil pump mini-wheel/lever steering
14. Switch normally open (NO) parking brake (S200) 35. Hydraulic oil pump for brake system and servo circuit for
15. Solenoid valve parking brake (Y642) load handling
16. Control valves for levelling, spreading and side shift 36. Control valve mini-wheel/lever steering
17. Solenoid valve levelling down (Y6022) or up (Y6023) 37. Solenoid valve steering right (Y615-1) and left (Y615-2)
18. Solenoid valve spreading in (Y6019) or out (Y6018) 38. Steering valve
19. Solenoid valve side shift left (Y6020) or out (Y6021) 39. Directional valve with solenoid valve steering forward
21. Solenoid valve lift (Y6005) or lower (Y6004) 40. Steering cylinder


page
–
20
19
22 20
21
22
23
17
24
26
25
14
15
18
13
12
27 28
29
16
11
9
10
31
8
29
30
6
33
1
2
5
3
009633 (A40750.3000 ver.1)

4
2
32
35
36
37
34
1

1. Wheel brake 21. Load holding valve

2. Brake cylinder 22. Tilt cylinder
3. Drive axle block 23. Flow divider
4. Hydraulic oil cooler 24. Side shift and spreading cylinders
5. Parking brake calliper 25. Levelling cylinder
6. Switch normally closed (NC) disengagement (S220) 26. Breather filter hydraulic oil tank
7. Switch normally open (NO) brake light (S216) 27. Hydraulic oil pump for steering and load handling
8. Shuttle valve, reversible operator’s seat 28. Hydraulic oil pump for lifting and tilting
9. Brake valve 29. High-pressure filter
10. Switch normally closed (NC) low brake pressure (S204) 30. Hydraulic oil pump mini-wheel/lever steering
13. Main valve 32. Control valve mini-wheel/lever steering
14. Switch normally open (NO) parking brake (S200) 33. Solenoid valve steering right (Y615-1) and left (Y615-2)
15. Solenoid valve parking brake (Y642) 34. Steering valve
16. Control valves for levelling, spreading and side shift 35. Directional valve with solenoid valve steering forward
18. Joy-stick 36. Steering cylinder
19. Load control valve 37. Hydraulic oil tank
20. Lift cylinder

16 E Schematics – 11 Common electrics
11 Common electrics
mm mm mm mm mm mm
Circuit diagram, description

page
–
A circuit diagram is divided into circuit names (drawing numbers) and

consists of a set of numbered pages.
The following is an explanation of symbols in circuit diagrams:
• 20015.0001 circuit drawings-post designations K-standard.
• K-standard 1: norms, rules
• K-standard 2: cables, general physical
• K-standard 5: Designation and marking system, item designations
circuit drawings
The following is an explanation of symbols and texts in a circuit dia-
gram:
Connectors
Connectors in the wiring start with an X followed by a number and end
-XM674m -XM674f
2 2 with f = female or m = male. If a connector is connected to a compo-
nent then the component number is inherited into the connector's
number, e.g. XB72002 Rm which is the connector for Sensor, align-
ment front right (B7202R).
Under the connector's number the pin is specifie with numbers or let-
013017
-X37-201 ters depending on the connector.

• X37-: All grounding points start with X37, e.g. X37-201, which is a
grounding point on the frame.
X37-A: X37-B, X37-C and X37-D are grounding points in
electronic box, cab.
Zero references are in the control units.
Components
+CHASSIS Components are described with component number (S220-2) and a
-S220-2 short descriptive text. Components (sensors, switches, etc.) are
P shown in standby mode i.e. de-energized or mechanically relieved po-
sition.
1 1 2 1
• S indicates the type of component, see Component designations,
013018
DECLUTCH
3,0MPa
page 18.
• 220 is component number and indicates the function the compo-
nent has.
• - 2 indicates that it is the second component of this type for the
specific diagram.

E Schematics – 11 Common electrics 17
Cable marking
A01012 0525 W212D

All cables are either white (ground signal) or grey (other wiring) and la-
belled with numbers.
Cable numbering is interpreted as follows:
A01011 0524 W212C
• 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
A01010 0523 W212B
• W212: cables that start with W and serial number cannot be
traced directly to a connector.
A01016 0527 W212E
• A01012: cables that start with A are in the electronic box in the
cab.
013019
W212A
• W212D: cables that end witha capital letter are jointed in the wir-
ing from a main cable with the same number. Each joint will have
its own letter.
References
0 A narrow symbo lmeans that the circuit continues on an other page in
the circuit diagram at the specified coordinates. Sometimes there are
1
00816 also references for components that can then be part of a component
/4.0_1.B1 5 1
013020
00816
whose other parts are on a different diagram. In some cases there is
/9.10_1.A2 also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.
Connection to control unit

Connections to control units are described as a table with two fields
the upper one shows the type of connection, the lower one has a ref-
-X411
21 K1:21 Analog In 0-5V +BOOM erence to the compilation of the control unit's connections. Together
/0.0_4.D5 -D791-1 with this there are descriptive texts that specify control unit and signal.
013021
MEASUREPOINT SCALE For more information about the different connection types on the con-
trol units, see section 11 Common electrics, group 11.5.5 Cables.
Fuses
Fuse boxes always start with F5. Example: F58-3 means fuse box 3
with 8 fuses.
For most fuse boxes there is also a table and an explanation of the cir-
cuits that the various fuses protect.

Component designations
page
–
The components in circuit diagrams have a prefix and number, the

prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is pro-
vided as an appendix after the circuit diagrams.
Prefix Description
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: operating hour gauge.
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
X Outlet/socket, connecting device Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.

Circuit diagrams, compilation

page
–
Circuit diagrams for basic machine has drawing number

A49842.0100, and are provided as an appendix in following order.
Sheet Designation
0.0-1 Circuit cross-reference ECU 790
1.0-A Circuit engine Volvo TAD650VE, TAD660VE,

TAD750VE and TAD760VE
1.0-B Circuit engine Cummins
1.0-C Circuit engine Perkins/Caterpillar
2.0-A1 Circuit, gear changing ECU 790
2.0-A2 Circuit, extra forward/reverse selector
2.0-A3 Circuit, gear changing, aut/ECU 793
2.0-A4 Circuit, gear changing, ECU 793
2.0-B1 Circuit, hydrostatic transmission
2.0-C1 Circuit, gear changing ZF
2.0-C2 Circuit, gear changing ZF
3.3 Circuit, differential lock
4.0-1 Circuit, cab
4.0-2 Circuit, cab VBFS
4.0-3 Circuit, monitoring brake pressure
4.5 Circuit, parking brake
5.2-1A Circuit, control function
5.2-1B Circuit, control function, VBFS
5.2-2A Circuit, control function
5.2-2B Circuit, control function, VBFS
7.0-1 Circuit, servo and hydraulic functions
7.0-2 Circuit, servo and hydraulic functions
7.0-3 Circuit, servo and hydraulic functions, VBFS
7.0-4 Circuit, ECU 796, joystick

Sheet Designation
7.0-5A Circuit, ECU 796, joystick 2
7.0-5B Circuit, ECU 796, joystick 2 VBFS
7.0-6A Circuit, hydraulic joystick
7.0-6B Circuit, hydraulic joystick, VBFS
7.2-1 Circuit, paper functions
7.2-2A Circuit, sensors attachment
7.2-2B Circuit, valves attachment
7.2-3 Circuit, indication lamps
7.2-4 Circuit, switches paper functions
7.2-5A Circuit, stop lower
7.2-6 Circuit, Optispeed/rev/lift
7.10 Circuit, electronic scale
8.2-1 Circuit, data com. RED CAN
8.2-2 Circuit monitoring
8.2-3 Circuit sensors speed and engine rev.
8.2-4 Circuit data com. J1939
8.2-5 Circuit data com.
9.1 Circuit sensors/instruments
9.2 Circuit, alcolocks
9.3-1 Circuit, seat rotation
9.3-2 Circuit, electric seat rotation
9.3-3 Circuit, seat up/down
9.3-4 Circuit, throttle application
9.4-1 Circuit, ECC
9.4-2A Circuit heating/AC
9.4-2AB Circuit heating/AC
9.4-3 Circuit heating/AC Flexcab
9.4-5 Circuit heating/AC
9.4-6 Circuit ECC fan
9.4-7 Circuit pause heater
9.5-1 Circuit, wipers
9.6-1 Circuit, headlights
9.6-2 Circuit, headlights
9.6-3A Circuit, headlights

Sheet Designation
9.6-3B Circuit, headlights, VBFS
9.6-4 Circuit, headlights, VBFS
9.6-5A Circuit, rear headlights, DCE90-
9.6-5B Circuit, rear headlights, DCE50-90
9.6-5C Circuit, rear headlights
9.6-6 Circuit working light
9.6-7 Circuit working light
9.6-8A Circuit working light
9.6-8B Circuit, working lights VBFS
9.6-9 Circuit light, engine bay
9.8-1 Circuit, cab
9.8-2 Circuit, compressor horn
9.14-1 Circuit option
11.5-1 Circuit power supply
11.5-2 Circuit power supply, fuses
11.5-3 Circuit power supply, fuses
11.5-4 Circuit power supply, ECU 792
11.5-5 Circuit power supply, ECU 793
11.5-6 Circuit power supply, ECU/EDU


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Kalmar Montacargas DCE 90-180, DCE 70-32E3-70-35E Workshop Manual (PDF - Io)

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64 D Error codes – 1 Engine

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

*) See component supplier documentation.

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Error codes transmission alternative

Dana TE13000 and TE17000

Description Limitation Action

00/51 Memory error in control unit Transmission locked in neu- -

00/52 Memory error in control unit Transmission locked in neu- -

00/53 Memory error in control unit Transmission locked in neu- -

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

46/05 Max. torque for inching has - -

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

77/02 All gear packs disengaged. Transmission locked in neu- -

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

90/xx - 99/ System error. Transmission locked in neu- -

95/71 Control unit cannot interpret - -

99/90 Incorrect software in control - -

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Error codes transmission alternative

Description Limitation Action

• Cable from shift lever to

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006- VDCE10.03GB

Description Limitation Action

VDCE10.03GB Workshop manual DCE 90–180, DCE 70-32E3–70-35E4 2006-

Description Limitation Action

5270/9 E5 DISPID1_timeout ECU793 select pa- Check display controller.