Hydrema 912C Rep - Man GB

REPAIR MANUAL
FOR
HYDREMA
912C
INDEX
1. GENEREL INFORMATION
2. ENGINE
3. TRANSMISSION
4. HYDRAULIC
5. CHASSIS / CAB
6. AEB - TEST PROGRAM
7. ELECTRICAL SYSTEM
8. INSTRUMENT DISPLAY
9. FRONT AXLE
10. REAR AXLE
11. SERVICE
12. A/C-SYSTEM
Machine type Group Page
Service 912C 1 1
Tightening torque for screws
The table below indicates the tightening torque values applicable. For fitted components
(diesel engine, transmission, etc.), the manufacturer’s instructions must be followed.
Figures in Nm
Screw Quality 5.8 Quality 8.8 Quality 12.9 Screw Quality 5.8 Quality 8.8
slotted screw hexagon head Allen screw UNC slotted hexagon
screw * screw head screw
M4 1.7 2.8 5.2 - - -
M5 3.5 5.5 10.5 1/4" 6.5 10.2
M6 5.9 9.3 18 5/16" 13.6 21
M8 14.2 23.1 43 3/8" 23 40
M10 - 46.3 87 7/16" 38 60
M12 - 80 150 1/2" 56 90
M16 - 187 360 5/8" 110 180
M20 - 374 700 3/4" 200 310
* for countersunk Allen screws quality 10.9, use this section.
Tightening torque for brackets
Manufacturer Type Pipe dimension Screw size Tightening torque N/m

Double ø12 M6 8.0
Stauff ø22
“green” Standard * ø25 M6 5.0
ø25
Heavy-duty ø25 M10 12.0
Hydrema Double ø12 M6 9.3
steel bracket Double/ ø15 M10 23.3
single ø18 M10 23.3
* Stauff “standard” is fitted with a washer.

Service 912C 1 2
Hydraulic connections
Fitting of pipes with ring fitting:
a) Cleanliness: Before mounting, wipe the pipe union, union nut and ring fitting
with a clean cloth under extremely clean conditions.
Apply hydraulic oil.
b) Tension: When fitting make sure that the fittings are not damaged at the
tapered part, and that the pipe is not under tension.
c) Tightening: Pipe/ring fitting is fitted into the pipe union.

The union nut should be carefully screwed on with a spanner until
the pressure point is reached.
The pipe union is held and the union nut tightened half a rotation.
Wipe the union nut clean of excess oil.
Fitting of pipe union:
a) Cleanliness: Before mounting, wipe the pipe union and the thread of the item.
b) Sealing: Thread tape - e.g., Crosslite. Applied to pipe unions with conical
thread (e.g., in cylinders) a suitable number of revolutions,
approx. 3-5.
As a minimum, sufficient tape should be applied to cover the

entire thread profile if one mounts and removes the pipe union.
Do not apply so much tape that the tape is pulled off when
mounting.
c) Tightening: The pipe unions are tightened according to the following torque
values.
Tightening torque for pipe unions with conical thread
Pipe union Tightening torque N/m

RC 1/4" 20
RC 3/8" 60
RC 1/2" 80
The elbows are tightened to the above torque and are then turned to the correct
position.
Service 912C 1 3
Tightening torque for pipe unions/pipe plugs with cylindrical thread

2
Pipe unions with Tightening Pipe plugs with Tightening
ring fitting or torque N/m rubber seal torque N/m
rubber seal
G 1/8" 17 G 1/8" 13
G 1/4" 40 G 1/4" 35
G 3/8" 65 G 3/8" 60
G 1/2" 110 G 1/2" 90
G 3/4" 210 G 3/4" 150
G 1" 300 G 1" 250
M 10x1 17 M 10x1 13
M 12x1.5 35 M 12x1.5 30
M 14x1.5 55 M 14x1.5 40
M 16x1.5 65 M 16x1.5 60
M 18x1.5 90 M 18x1.5 70
M 20x1.5 110 M 20x1.5 90
M 22x1.5 130 M 20x1.5 100
M 26x1.5 210 M 26x1.5 120
M 27x2 240 M 27x2 150
M 30x2 300 M 30x2 250
Fitting of pipes with conical fittings (JIC 37°):
a) Cleanliness: Before mounting, wipe the pipe union, union nut and ring fitting
with a clean cloth under extremely clean conditions.
Apply hydraulic oil.
b) Tension: When mounting make sure that the pipe is not damaged at the
tapered part, and that the pipe is not under tension.
c) Tightening: The union nut should be carefully screwed on by hand until the
pressure point is reached.
Tighten the union nut min. ¼ and max. ½ rotation (or see table).
Tightening torque for union (JIC 37o)
Type JIC 37° Tightening torque N/m

ø 25 min. 119 max. 180
Service 912C 1 4
Gluing with Loctite
Internal thread: Clean with UNISOL 50l and water in mixture ratio 1:10.
Apply Rocol Heavy Duty Cleaner Spray 00225.
Rinse in clean water and blow-dry with compressed air.
External thread: Clean with UNISOL 50l and water in mixture ratio 1:10.
(Loctite 243)
Mount with Loctite 243 (899653) under extremely clean conditions.
External thread: Clean with UNISOL 50l and water in mixture ratio 1:10.
(Loctite 270)

“The joint is not normally intended for disassembly.”
Hydraulic seals: Clean with UNISOL 50l and water in mixture ratio 1:10.
(Loctite 542)
Drying time: Min. ½ hour before immersion in oil.

Service 912C 1 5
Axle/hub joints
1
Axle/hub joints on the vehicle are all

designed according to the same principle, 2
fig.1.
A hub with lining (pos.5-6) (Glacier bush 3
bearing) is locked onto a tempered axle
(pos.2). 4
The axle is put into the bracket (pos.1)
with fit: J7/h7.
The axle is locked to the bracket using a
locking element (pos.3) and an M12
screw (pos.4). 6 5
Figure 1
Removal of axles
The axles can be removed according to different methods depending on the tools available.
3 methods are described in the following.
1. Removal with impact puller

The instructions apply to removal with manual “impact puller”.
Equipment: impact puller

ring spanner/fixed spanner 19 mm
2 1
M30
3 4
Figure 2
a) remove M12 screw (pos.4) and locking element (pos.3)

b) screw the impact puller (pos.1) into the axle - the impact puller must be screwed
in to a sufficient depth so that all threads in the axle are under load
c) remove the axle (pos.2)
Service 912C 1 6
2. Removal with puller tools
The instructions apply to removal with manual “puller tools”.
Equipment: puller (090099)

adjustable spanner
4 3 2 1
M30
5 6
Figure 3
a) remove M12 screw (pos.6) and locking element (pos.5)

b) screw the puller axle (pos.1) into the axle (pos.4) - the puller must be screwed in
to a sufficient depth such that all threads in the axle are under load
c) place the spacer (pos.3) and washer (pos.2) against the bracket and tighten the nut
d) tighten the nut and pull the axle out of the bracket
Service 912C 1 7
1. Removal with hydraulic puller tools
The instructions apply to removal of the axle with hydraulic “puller tools”.
Equipment: hydraulic puller tools (090055)

adjustable spanner
2 1
750 bar
5
8
M30
3
4
6 7
Figure 4
a) connect the hydraulic press (pos.1) to the compressor (4-way valve (pos.2) is used
to determine the direction of the hydraulic cylinder (pos.4))
b) remove M12 screw (pos.7) and locking element (pos.6)
c) screw puller axle (pos.3) into the axle - the puller must be screwed in to a
sufficient depth such that all threads in the axle are under load
d) place the spacer (pos.5) and the puller cylinder (pos.4) against the bracket and
tighten the M30 nut
e) the puller cylinder should be put under pressure by activating the foot-pump
f) pull the axle (pos.8) out of the bracket
Service 912C 1 8
Mounting of axles
The instructions describe the general mounting of axles on the vehicle - see fig.1.
Equipment: hammer - 2 kg
cleaning agent - rust-remover
Tectyl
screw M30 DIN 933
adjustable spanner
a) clean any rust from the holes in the bracket - the holes must not be abraded with
emery cloth or any similar material
b) position the hub opposite the centre of the hole in the bracket
c) clean any dirt from the axle - the axle must not be abraded with emery cloth or
any similar material
d) spray Tectyl onto the axle
e) screw M30 set screw DIN 933 into the axle
f) carefully hammer the axle into the outer plate of the bracket. It is extremely
important that the axle is not hammered obliquely into the bracket as this can
damage the surface of the hole. It is also important that the hub is positioned
exactly opposite the centre of the axle - so that the lining is not damaged
g) hammer the axle all the way through the bracket
h) lock the axle with the locking element and M12 screw
Service 912C 1 9
Foot pounds Kilogram Newton Newton Kilogram Foot pounds Kilogram Newton Foot pounds
(ft-lb) meters meters meters meters (ft-lb) meters meters (ft-lb)
(Kgm or mKg) (Nm) (Nm) (Kgm or mKg) (Kgm or mKg) (Nm)
5 0,69 6,78 5 0,51 3,69 1 9,81 7,2
10 1,38 13,56 10 1,02 7,38 2 19,61 14,5
15 2,07 20,34 15 1,53 11,06 3 27,42 21,7
20 2,76 27,12 20 2,04 14,75 4 39,23 28,9
25 3,46 33,90 25 2,55 18,44 5 49,03 36,2
30 4,15 40,68 30 3,06 22,13 6 58,84 43,4
35 4,84 47,46 35 3,57 25,81 7 68,65 50,6
40 5,53 54,24 40 4,08 29,50 8 78,45 57,9
45 6,22 61,02 45 4,59 33,19 9 88,26 65,1
50 6,91 67,80 50 5,10 36,88 10 98,07 72,3
55 7,60 74,58 55 5,61 40,57 11 107,87 79,6
60 8,29 81,36 60 6,12 44,26 12 117,68 86,8
65 8,98 88,14 65 6,63 47,94 13 127,49 94,0
70 9,67 94,92 70 7,14 51,63 14 137,29 101,3
75 10,37 101,70 75 7,65 55,32 15 147,10 108,5
80 11,06 108,48 80 8,16 59,01 16 156,91 115,7
90 12,44 122,04 85 8,67 62,69 17 166,71 134,0
100 13,82 135,60 90 9,18 66,38 18 176,52 130,2
110 15,20 149,16 95 9,69 70,07 19 186,33 137,4
120 16,58 162,72 100 10,20 73,76 20 196,13 144,7
130 17,97 176,28 105 10,71 77,44 21 205,94 151,9
140 19,35 189,84 110 11,22 81,14 22 215,75 159,1
150 20,73 203,40 120 12,24 88,51 23 225,55 166,4
175 24,19 237,70 130 13,26 95,89 24 235,36 173,6
200 27,64 271,20 140 14,28 103,26 25 245,17 180,8
225 31,09 305,10 150 15,30 110,64 26 254,97 188,1
250 34,54 339,00 160 16,32 118,02 27 264,78 195,3
275 38,02 372,82 170 17,34 125,39 28 274,59 202,5
300 41,47 406,75 180 18,36 132,77 29 284,39 209,8
350 48,39 474,54 190 19,38 140,14 30 294,20 217,0
400 55,30 542,33 200 20,40 147,52 31 301,01 224,2
450 62,21 610,12 210 21,42 154,90 32 313,81 231,5
500 69,13 677,91 225 22,94 165,95 33 323,62 238,7
550 76,04 745,70 250 25,50 184,40 34 333,43 245,9
600 82,95 813,49 275 28,04 202,83 35 343,23 253,2
650 89,86 881,28 300 30,60 221,29 36 353,04 260,4
700 94,78 949,07 325 33,14 239,71 37 362,85 267,6
750 103,69 1016,86 350 35,70 258,30 38 372,65 274,9
800 110,60 1084,66 375 38,24 276,59 39 382,46 282,1
850 117,51 1152,45 400 40,80 295,20 40 392,27 289,3
900 124,43 1220,24 450 45,89 331,90 45 441,30 325,5
950 131,34 1288,03 500 50,98 368,78 50 590,33 361,7
1000 138,25 1355,82 550 56,08 405,66 55 539,37 397,8
600 61,18 442,54 60 588,40 434,0
650 66,28 479,41 65 637,43 470,2
700 71,38 516,29 70 686,47 506,1
750 76,48 553,17 75 735,50 542,5
800 81,58 590,05 80 784,53 578,6
850 86,68 626,93 85 833,57 614,8
900 91,78 663,80 90 882,60 651,0
950 96,87 700,68 95 931,63 687,1
1000 101,97 737,56 100 980,67 723,3
Service 912C 2 0
REPAIR
MANUAL
FOR
HYDREMA 912C
DUMP TRUCK
STAGE 2
ENGINE
Maskintype Gruppe Side
Service 912C 3 1
Service 912C 3 2
Service 912C 3 3
ZF - EST 37
DIAGNOSTIC
INSPECTION
AND
TROUBLE SHOOTING
Typeplate
Service 912C 3 4
ZF-DISPLAY.
Display:
If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows
the fault code, if the gear selector is on neutral.
If more than one fault is detected, each fault code is shown for about 1 second.
CAN-message:
The TCU sends the fault code of a detected fault in specified CAN-message, while the fault
is active.
If more than one fault is detected, the fault code scrolls.
Description of fault codes:
First number Meaning of the number

1 HEX Digital indput signal
2 HEX Analog indput signal
3 HEX Speed signal
4 HEX CAN signal error
7 HEX Analog current output signal
8 HEX Analog current output signal
9 HEX Digital output signal
A HEX Digital output signal
B HEX Transmission fault, clutch error
C HEX Logical current
D HEX Power Supply
E HEX High speed signal
F HEX General fault
Service 912C 3 5
Abbreviations:
o.c. open curcuit

s.c. short curcuit
OP-Mode operating mode
TCU transmission control unit
EEC electronic engine controller
PTO power take off
Service 912C 3 6
Definitions of operating modes:
Normal:
There’s no failure detected in the transmission-system or the failure has no slight effects
on transmission control. TCU will work without or in special cases with little limitations.
(See following table).
Substitute clutch control:

TCU can’t change gears or the direction under the control of normal clutch modulation.
TCU uses the substitute strategy for clutch control. All modulations are only time con-
trolled. (Comparable with EST 25).
“Limp-home”:
The detected failure in the system has strong limitations to transmission control. TCU can
engage only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the
operator must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear
selector into forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed TCU will shift immediately into
limp-home gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral.
The operator has to slow down the vehicle and must shift the gear selector into neutral
position.
Transmission-shutdown:
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply
(VPS1).
Transmission shifts to neutral. The park brake will operate normally, also the other func-
tions which use ADM1 to ADM8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU-shutdown:
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also common power supply (VPS1, VPS2). The
park brake will engage, also all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
Service 912C 3 7
Service 912C 3 8
Service 912C 3 9
Service 912C 3 10
Service 912C 3 11
Service 912C 3 12
Service 912C 3 13
Service 912C 3 14
Service 912C 3 15
Service 912C 3 16
Service 912C 3 17
Service 912C 3 18
Service 912C 3 19
Service 912C 3 20
Service 912C 3 21
Service 912C 3 22
Service 912C 3 23
Service 912C 3 24
Service 912C 3 25
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Service 912C 3 27
Service 912C 3 28
Service 912C 3 29
Service 912C 3 30
Service 912C 3 31
Service 912C 3 32
Service 912C 3 33
13 14
Service 912C 3 34
Service 912C 3 35
Service 912C 3 36
Service 912C 3 37
1.3 Display in work
Symbol Meaning Remarks

1F, 1R In gear and driving direction
2F, 2R Left character show the chosen gear
3F, 3R Right character show the chosen driving direction
4F
5F
6F
LF, LR ’limp home’ gear
F or R - no Clutch disengaged.
gear
F or R Only 6WG:
flashing Driving direction F or R chosen while turbine
revolutions are to high.
NOTE: Gear are chosen when rev. drops.
NN Not Neutral, wait for Neutral after ignition or severe To select a gear, gear selector in
failure have occurred Neutral and then again into F or R
position.
** Oil temperature too low, no gear available. Engine/Transmission must be heated
up.
*N Oil temperature too low, only one gear available. Engine/Transmission must be heated
up.
1 Beam Manuel modus / 1. gear
(special
symbol)
2 Beams Manuel mode / 2. gear
4 Beams + 2 Automatik-mode
arrows
Beam flashes Transmission coupling of torque converter is open. The difference between the
revolutions og engine and turbo is
exceeding a given limit and the
converter coupling is not activated.
Folk spanner At least one error. Set gear selector in neutral to see the
error code in the display.
Error code See error code list
WS Warning signal – sump temperature Shift between selected gear /selected
direction of travel while driving. Is
shown while in neutral position only
if the error is not found (spanner).
WR Warning signal – retarder temperature Shift between selected gear /

selected direction of travel while
driving. Is shown while in neutral
position only if the error is not found
(spanner)
WT Warning signal – temperature of torque converter Shift between selected gear /
(spanner)
WE Warning signal – high number of revolutions. Shift between selected gear /

Service 912C 3 38

(spanner)
PN Driving direction F or R is chosen while parking brake Transmission in neutral until

is activated. Parking brake is deactivated.
F or R flashes Direction of travel F or R selected, while turbo NOTE: select gear when the turbo
revolutions too high revolutions are falling.
EE flashes No communication with display. The cable connection between TCU
and display must be checked.
Service 912C 3 39
The display while in AEB mode
Symbol Explanation Notes

PL AEB starting motor connected to the
diagnosis plug.
ST Button of the AEB starting motor
activated.
K1, K4, KV, KR Steering is now calibrating K1, K4, KV
and KR respectively.
_ and Kx Wait for ignition, steering is preparing
the calibration of Kx.
x: 1,2,3,4,V, R
≡ and Kx The steering finds the time for the quick
charging of the coupling Kx.
= and Kx The steering finds the equalizing
pressure for charging the coupling Kx.
OK Calibration of all couplings finished. Transmission stays in neutral. When
having disconnected the AEB starting
motor start ESG again (ignition
ON/OFF).
STOP AEB interrupted (activation stopped) Transmission stays in neutral. Start ESG
again (ignition ON/OFF).
STOP and Kx AEB interrupted, coupling Kx cannot be Transmission stays in neutral. Start ESG
calibrated. again (ignition ON/OFF).
Screwdriver and Kx Kx could not be calibrated, AEB Transmission stays in neutral. Start ESG
finished. again (ignition ON/OFF).
▲ E Revolutions too low => must be
increased.
▼ E Revolutions too high => must be
reduced.
▲ T Transmission oil temperature too low
=>transmission must be heated.
▼ T Transmission oil temperature too high
=> transmission must be cooled.
FT Transmission temperature during the Transmission stays in neutral. Start ESG
calibration is not within the fixed range. again (ignition ON/OFF).
FB Mode of operation not NORMAL or Transmission stays in neutral. Start ESG
temperature sensor of the transmission again (ignition ON/OFF).
defect or it is not possible to enter the
calibrated values in EEPROM.
FO Outlet revolutions are not on 0. Transmission stays in neutral. Start ESG
FN Gear selector not in neutral position. Transmission stays in neutral. Start ESG
FP P-brake not activated. Transmission stays in neutral. Start ESG
STOP AEB – starting motor has not been used Transmission stays in neutral. Start ESG
correctly or it is defect. Wrong tool again (ignition ON/OFF).
connected or wrong adapter used.
Service 912C 3 40
Data of the 3 Inductive transmitters of Engine, Turbine and Central gear train.
Resistance: 1050 Ohm (+/- 10%) at 200C
Temperature range: -400C ---> + 1500C
Torque limit: 30Nm
Data for Hall-Sensor of the Output.
Temperature range: -400C ---> + 1500C
Working range: 2Hz ---> 5 Khz
Supply voltage: 24 V
Data for Proportional valves.
Resistance: 19Ohm (+/- 10%) at 200C
Current: 100 ---> 500mA
Pressure range: 0,8 bar ---> 8,3 bar
Data for temperature sensors.
Sump: 1000 Ohm ---> 1500 Ohm
Retarder: 800 Ohm ---> 1500 Ohm
Data for solenoid valve.
Lock-up clutch:
- Resistance: 60 Ohm ---> 80 Ohm
- Current: 0,25 A ---> 0,35 A
- Voltage: 24 V
Data for:
- Control pressure: 16 +2 bar

- Lubrication pressure: 0,2 ---> 1,5 bar
- Pressure before the converter: 11 bar
- Pressure behind the converter: 1,5 bar
- Oil-flow from the pump: 50 l/min at 2.000 Rpm.
Type of machine Group Page
Service 912C 4 1
TEST & ADJUSTMENT

-----
HYDRAULIC SYSTEM
Service 912C 4 2
HYDRAULIC SYSTEM
The machine has two hydraulic pumps. One pump supplies the steering gear and tilting
function. The oil is distributed between these two functions by means of a priority valve.
The second pump supplies the main brake and the parking brake as well as the hydraulic
stabilizers.
The pump for steering gear and tilting function is a 36 cm3 gear pump mounted on the back
of the transmission. The oil gives priority to the steering which has a working pressure of
200 bar.
The Orbitrol steering unit controlled by LS works as an emergency pump in case the oil
supply from the steering pump stops. The unit is mounted with 2 overload valves of 250 bar.
The working pressure for the tilting function is 200 bar.
The pump for brake and stabilizer is a 10 cm3 gear pump mounted on the front of the
Perkins engine. The working pressure is 60 bar. The oil is sent from the steering pump to
the charge valve of the system. This charge valve supplies the brake system and its 2
accumulators. Then the oil is sent to the valve block of the charging system. P is the inlet
for the oil which supplies the stabilizers through C.
The accumulator, pos.8, is directly connected with the charging circuit P and C. At max.
stroke of the stabilizer the relief valve, pos.7, opens and leads the odd oil into the tank.
The pressure reducing valve pos.6 reduces the pressure in the charging circuit to 20 bar.
The reduced pressure supplies the P-brake A, as soon as the solenoid valve, pos.4, is
activated. By activating the solenoid valve, pos.5, the differential lock B is supplied with the
reduced pressure. The relief valve, pos.7, is set to 68 bar and works as safety valve for the
charging circuit. The solenoid valve, pos.3, for the pendulum lock is optional.
The machine is equipped with 2 hydraulic stabilizers having a working pressure of 68 bar.
The main brake pressure in the axle in front and in the rear is 23 bar.
The parking brake, a fail-safe type, is integrated in the front axle and activated electric-
hydraulically.
The brake pressure for the P-brake is 20 bar. The P-brake can be deactivated mechanically
by means of 6 Allen screws situated on the front axle.
Service 912C 4 3
Fig. 1
1: Measuring outlet for charging pressure (40 - 60 bar)

2: Measuring outlet for reduced pressure (20 bar)
3: Solenoid valve for pendulum lock
4: Solenoid valve for P-brake
5: Solenoid valve for differential lock
6: Pressure reducing valve (20 bar ±1)
7: Relief valve for the stabilizers (68 bar)
8: Accumulator, pre-charging pressure: 14 bar, volume 0.75 ltrs.)
9: Valve block (aluminium)
Control of the reduced pressure:
To make the P-brake (negative brake) work satisfactorily it is important that the pressure is
adjusted correctly. A low pressure, for example, would damage the brake, as it would not
slip the clutch disks in the front driving axle, and consequently the P-brake would heat up.
Adjust the engine to 1000 rpm and check that there is charging pressure available, pos.1.
Afterwards measure the reduced pressure, pos.2. This pressure must be 20 ±1 bar. Any
adjustment can be made with the Allen screw at the end of the pressure reducing valve,
pos.6.
Service 912C 4 4
Stabilizer
The machine is fitted with 2 hydraulic stabilizers. These stabilizers are fitted with a piston
rod and two loose pistons for resistance (45-140 bar). The pressure connection is situated
in the middle of the stabilizer, and the two ends are connected to the tank to absorb any
leaks. This means that the stabilizers can build up traction only.
When the machine is oscillating, the stabilizers will always oppose the movement and try
to move the machine back into neutral position. The oscillation is stopped mechanically by
the piston rod touching the bottom of the cylinder pipe.
As the stabilizers are connected to the accumulator, they have the function of a "hydraulic
spring", that means the resistance against the oscillation is increasing along with the number
of oscillations of the machine.
Note ! The stabilizers do not oppose to the steering.
Fig. 2
The oscillation angle is: +/- 12º

Service 912C 4 5
CONTROL AND ADJUSTMENT.
Pump pressure at 2000 rpm: max. 200 +/- 5 bar.

Measuring point: Fig.. 4, pos. 1.
To adjust with the relief valve (see fig. 3) on the control valve (fig. 4, pos.2).
Back
Tilting - multitip
Turn multitip/Tilting – rear tipping
Pressure adjustment
Inlet
Fig. 3
The hydraulic pressure for the steering pressure is controlled by holding the cylinder in
bottom position for min.10 seconds at 1500 rpm: 200 +/- 10 bar.
Fig. 4
Measuring point: pos. 1, fig. 4.
Control of the oil supply for steering and tilting function:
Rear tipping:
Tipping time at 2000 rpm without activated steering gear: 8 ±1 sec.
Multitip:
Tipping time at 2000 rpm without activated steering gear: 10 ±1 sec.
Tipping start at 1100 to 1350 rpm with activated steering gear.
Service 912C 4 6
Charge pressure: min. (the charging is starting) 40 +6/-2 bar

max. (the charging is finished) 60 ± 6 bar
Measuring point (pos. 1, fig. 1)

Adjustment not possible, as the factory setting of the charge valve was made with a spring
set.
Interval between 2 charges without activated hydraulics, but with activated P-brake:
minimum 4 min.
Interval between 2 charges without activated hydraulics and P-brake:

minimum 2 min.
Brake pressure:
Pedal held in bottom pos. with slight load towards the pedal stop: 23 +2/-0 bar.
Measuring point, front axle (pos.1, fig.6)
Measuring point, rear axle (pos.1, fig. 6)
Adjustment
Fig.5
Parking brake:
Not activated 20 ± 1 bar.
Measuring point (pos.2, fig.1)

The adjustment is made on the pressure reducing valve (pos.6, fig.1)
Service 912C 4 7
1
Fig.6
Stoplight switch: 2,5 +0,5/-0 bar.

The adjustment is made with the adjusting screw between the two cable terminals
(pos.2, fig. 7)
Fig.7
Switch – charge control (pos. 1, fig. 7): 28 ± 1 bar.

Service 912C 4 8
Servo connection between joystick, fig.8, pos.1 and control valve, pos. 2.
The hydraulic connection leads from the joystick to the control valve, with a valve as
hydraulic lock situated between the inlet side of the joystick and valve block fig. 1.
This lock is electrically controlled by means of a pushbutton that is mounted on the back
side of the joystick handle, see pos. 1, fig. 9.
Servo pressure: min. 17 bar
max. 20 bar
Measuring point, fig. 1, pos. 2.
Fig. 8
Fig. 9
Service 912C 4 9
Arm rest - adjustments
Normal adjustment
Adjustment leverr
Individual adjustment:
It is possible to make a minor angle

adjustment by using washers in
front or behind, between the arm
rest and the console.
In the console there are fri holes,

ø15mm, where the 2 screws M10
are fixed allowing to make a side
adjustment of ±10 mm.
The control lever is mounted into

oplong holes allowing a rotation of
± 4º.
Service 912C 4 10
Steering unit
The steering unit is supplied with oil by a hydraulic pump mounted on the transmission.
The oil is transported from the hydraulic pump through a priority valve, which determines the
priority of the oil for the steering – for the sake of safety.
The odd oil or the whole oil quantity – if the steering wheel is not activitated – can be used
for the working hydraulics. This odd oil is controlled by the LS-signal sent from the steering
unit to the priority valve which itself adjusts the oil quantity to the steering unit.
To avoid a lack of steering pressure, the pressure pipe is equipped with a sensor of 4 bar.
The steering unit is equipped with an emergency pump.
The steering unit is also equipped with 2 chock valves of 250 bar, and a valve for the steering
pressure. this valve is adjustable, but has a factory setting of 200 bar..
Service 912C 4 11
Steering unit.
Service 912C 4 12
COMPONENTS LIST FOR HYDRAULIC DIAGRAM
1. Hydraulic pump 36 ccm

2. Hydraulic pump 10 ccm
3. Hydraulic tank
4. Back-flow filter
5. Control valve
6. Charge valve
7. Safety valve
8. Control valves, multitip
9. Steering unit ORBITROL
10. Priority valve
11. Steering pressure alarm
12. Brake valve
13. Stoplight switch
14. Accumulator
15. Charging pressure alarm
16. Valve block - pendulum lock, pressure reduction, P-brake and differential lock
17. Valve, hydraulic lock
18. Servo lever
19. Throttle valve
20. Stabilizer
21. Tilting cylinder, rear side tipping
22. Swing cylinder, multitip
23. Telescopic cylinder, multitip
24. Steering cylinder
SERVICE 912C 5 1
Chassis
SERVICE 912C 5 2
General description
Articulated chassis consisting of 2 main parts: the front frame and the rear frame.
The frames are connected in the articulation above and the pendulum bar below. There are 2
hydraulic stabilizers in the articulation.
The fuel tank and hydraulic tank are integrated in the front frame.
Steering angle: ± 35o

Oscillating angle between front and rear axle ± 12o
Articulation
The articulation is suspended in a ball fitting of ø90mm (pos.3). This ball fitting takes up both
radial and axial forces. It is therefore important that the ball fitting is fixed by a thrust washer
(pos.6) and lock washer (pos.4). The Allen screw must therefore be tightened to the following
moment:
M10 US. Allen screw (pos.5) 47 Nm

M16 Allen screw (pos.7) 360 Nm
It is important for the life of the ball

bearing (pos.3) that it is greased
continuously. A long life can only be
achieved with an impeccable seal
ring (pos.2). If it is damaged, it has to
be replaced.
To replace the seal ring it is

necessary to dismantle the
articulation.
The axle (pos.1) can be pulled out

with a puller (M30), when the
hydraulic pump 74cm3 is dismounted.
WARNING !
The machine has to be stabilized
before the axle (pos.1) is
dismounted.
Service 912C 5 3
Pendulum bar
Both ends of the pendulum bar are bedded in a ball fitting of ø60. These ball fittings take up
mainly radial forces, but the 2 stabilizers contribute with axial forces. The thrust washer
(pos.7) fixes the axle (pos.1) and makes sure that the axle does not start turning in the fit of
the pendulum bar. The Allen screws (pos.8) must therefore be tightened to the following
moment:
M10 Allen screw: 87 Nm
It is important for the life of the ball

bearing (pos.4) that it is continuously
greased. A long life can only be
achieved with impeccable seal rings
(pos.2 and pos. 6). If they are
damaged, they have to be replaced.
To replace the seal rings it is

necessary to dismantle the pendulum
bar.
The axle (pos.1) can be pulled out

with a puller (M30), when the prop
shaft is dismounted.
WARNING !
The machine has to be stabilized
before the axle (pos.1) is dismounted.
Steering cylinder
Both ends of the steering cylinder are

bedded in a ball fitting of ø30mm in
such a way that the steering cylinders
can move, and the machine can
consequently turn ±35o and swing ±12o.
The seal ring (pos.2) protects the ball

fitting against dirt from above. This seal
ring has to be impeccable to achieve
the calculated duration of life.
The distance rings (pos.6) are ment to

fix the seal ring and to limit the turning
radius (up/down) of the steering
cylinder to max. 8o. In this way the
scrapers on the ball fitting cannot be damaged, when the machine is swinging
SERVICE 912C 5 4
Cab suspension
The cab is suspended in a 2-point suspension system.
Denomination: 1. Monroe shock absorber

2. Reaction arm (side)
3. Vibration absorber
The 2 shock absorbers (pos.1) constitute the suspension in the rear and take the vertical
load, while the reaction arms (pos.2) take the horizontal load. The reaction arms ensure that
the cab does not swing too much in bends or when driving off-road. Consequently, the
meaning of the reactions arms is to force the cab into mainly vertical movements. In the front,
the cab has normal rubber vibration absorbers.
The shock absorbers consist of a coil spring taking the load and a gas cylinder acting as a
damping element.
Travel of the shock absorber: approx. 45 mm

When "shaking" the cab it should stop again after a few oscillations, otherwise the shock
absorbers have to be exchanged.
3 1
2
SERVICE 912C 5 5
Exchange of glued panes
Before starting, following preparations have to be made:
The surface must be clean and dry, dust and loose particles like old glue, paint, rust etc. must
be removed. The existing glue has to be removed to apply a new thick layer. Only material
recommended by Hydrema should be used. Never apply glue on painted surfaces. The
window corners must be smooth.
Instruction
1. When taking the old window out, or the remains of it, you can use a pocketknife.
Cut along the edge of the glass.
2. Old glue can be removed from the cab with a suitable chisel or knife. If the silicone
sealing strip inside the window frame has hardened, it can be cut down to 1 mm
approx. If it has not hardened, the area must be totally cleaned. Remains of rust must be
removed.
3. Place the pane in the frame by means of spacers to avoid that the glass corners can
touch the window frame. The pane can be lifted and put down with suckers.
4. Preparations for gluing. Apply SikaRustPrimer on the clean surfaces by using a plastic
cartridge, sponge or paint brush. The SikaRustPrimer is ready after approx. 15 minutes.
Areas covered with hardened sealing compound have to be cleaned with SikaCleaner-
205A. Use a plastic cartridge, sponge or paint brush. The SikaCleaner-205A is ready
after approx. 5 minutes.
WARNING !
Avoid skin contact with the primer and cleaner. Do not inhale the primer or cleaner. Always
use clean material or equipment. Always close the tin with the primer or cleaner after use.
5. Adjust the tip of the glue cartridge by removing the little pin. Remove the seal at the
bottom of the cartridge and puncture the tube in the thread end. Place the cartridge in the
tool. Applying the glue with a manual gun or an air gun with movable piston would be
most efficient. Apply the glue at an angle of 90o onto the window frame. Minimum
height: 9 mm. Minimum width: 8 mm. Both SikaFlex-255Fe and SikaTack Ultrafast can be
used for the fitting. If the old glue has not been removed, it is necessary to use SikaFlex-
255FC.
6. Fitting the pane. Place the pane with its ceramic edge upwards and apply Sika-
Cleaner-205A. Ready after 15 minutes.
WARNING !
If you waste primer or cleaner on the glass, remove it at once. Primer and cleaner
can attack the pane. Primer and cleaner can be removed with SikaRemover or a similar
product.
SERVICE 912C 5 6
7. Fitting the window. Lift the window with suckers and press it onto the window frame.
Use the same pressure all over the pane until the window is just below the cab corner
(approx. 2 mm). Support the window with spacers. Use spacers or distance blocks to keep
the two door panes from each other. While hardening, the front and rear window must be
kept in position with straps or suckers. The side windows 2x2 in the doors must be fitted in
the same way.
Be aware that the panes should be pressed into position slowly and carefully, because
they can bulge out.
8. Weatherproofing the 2 windows and doors. The joints must be cleaned with Sika-
Cleaner205A. Weatherproofing with SikaFlex-521 is must efficient.
9. Cleaning. The odd material on cab or window can be removed with SikaRemover. The
glued strips can be smoothed out with soapy water and a piece of wood.
10. Hardening time of glued windows.

For SikaFlex-255FC: after 4 hours, when using the window gently. Ready for normal use
after 24 hours.
For SikaTrack Ultrafast: after 1 hour, when using the window gently. Ready for normal
use after 8 hours.
The above hardening duration of both glues depends on an air temperature of 20oC and
an air humidity of 65 %.
11. Safety: Follow the instructions indicated on the packing of the products.
Service 912C 6 1
TESTING
THE ZF-TRANSMISSION
ON THE HYDREMA 912C
PROGRAMS IN
PORTABLE COMPUTER
Service 912C 6 2
To control the ZF-transmission on the Hydrema 912C you need the following:
- Portable computer (Windows 95 or 98/NT).
- DPA 03 (adaptor for diagnosis and programming)

This adaptor is only to be used with Windows 95.
- DPA 04 (adaptor for diagnosis and programming)

This adaptor can be used with Windows 95/98/NT/Me and XP.
- Adapter cable (between machine and DPA 03 or DPA 04).
The computer is either battery-powered or can be connected to 220V or 12V on

the machine to be controlled.
Having started the computer, highlight the icon with the text ”ZF-912-926C”
and the following display appears on the screen:
Highlight PAL2 Application.

Pinpoint (with the right mouse button) the field RUN.
Press ENTER
Service 912C 6 3
Pinpoint SELECT
Press ENTER
Pinpoint WG110.app.
Press ENTER.
Pinpoint RUN.
Service 912C 6 4
Click on √or press ENTER and the display Safety instructions appears on the
screen:
To continue: click on √ and WG110 product menu appears:

Service 912C 6 5
Pinpoint Repair assistance, press ENTER and the text

’Does not yet exist in this version’ appears.
Click on √ or press ENTER and you return toWG110 product menu .

Service 912C 6 6
Click on TIPS or highlight the line and press ENTER.
A new display with Tips appears. These tips do not exist in this version. Therefore,
highlight
Return to menu and press ENTER:
Service 912C 6 7
The display WG product menu appears again.
Highlight Diagnosis, press ENTER and Connect Laptop appears:
Connect the portable computer with the machine as shown in the next display, and then
connect the ignition.
Service 912C 6 8
CONNECTING THE DIAGNOSIS ADAPTER DPA 03 AND ADAPTER CABLE
Diagnosis cable for

EST 37
To the computer
Always in pos. AUS
Not in use
Flashing when in
use
Lights when in Always in pos. KL30
use
Service 912C 6 9
CONNECTING THE DIAGNOSIS ADAPTER DPA 04AND ADAPTER CABLE
To Laptop
Port ISO
9141 Port SAE J178 not in use on
connected EST-37
to the plug
in the
machine
UBatt lights when the

machine power is
between 12 - 24V
DATA lights when

data is transfered
from the machine
L - Ltg. not in use when

EST-37 is connected
Always in
possition
”AUS”
Always in kl.30
Service 912C 6 10
Having connected the computer to the machine and connected the ignition click on √,
press ENTER and the display Information appears:
The red diode marked DATA on the DPA03/DPA04 is flashing (input of data) . When this
is finished, the display is shifting automatically to Diagnosis:
Service 912C 6 11
Pinpoint Read Error Memory, press ENTER and the display Read Error Momory with
the error list appears:
Here it is possible to pinpoint the possible error. Then press ENTER and the corresponding
error message Fault data appears on the next display, followed by other possible errors
which may be in the system. If you do not wish to see the errors, pinpoint Retur to menu
and press ENTER.
On the next pages you can see how error messages are listed on the screen.
Fault data - Error number D3H, code D3 is to be found in sheet section 3 - Error ferequency
14, this is the number of this failure apperence since last fault data deleting.
Click on 4and press ENTER to shift to the next display.

Service 912C 6 12
The next displays are showing the failure list. Preserve the list on a diskette. In this way all
the failures are registered in the EDP system.
The last line appears on the next display as the first line, which appears when clicking (with
the mouse) on the key ▼.
Next page: key ▼, last page: ▲.

Service 912C 6 13
Next page: key ▼, last page: ▲.
Last page: key ▲
To return to the display Diagnosis click (with the mouse) on the key √ or press ENTER.
Service 912C 6 14
Highlight the line Read Error Memory and press ENTER to return to the display Read
Error Memory.
In this display you can highlight one of the items and click with the mouse on the question
mark ‘?’ to get information about the various abbreviations and keys.
Press ENTER or click on the right √ to return to the display Diagnosis.

Service 912C 6 15
Back in the display Diagnosis, highlight Delete Error Memory, press ENTER or click on
√ and a new display appears on the screen.
Here you have to choose YES or NO.

If you highlight No and press ENTER you return to the display Diagnosis and all the errors
stay in the memory.
WARNING! IF YOU HIGHLIGHT YES AND PRESS ENTER, VARIOUS ERRORS

WHICH MAY BE IN THE MEMORY ARE DELETED IN THE MEMORY.
Before errors are deleted, they have to be preserved on a diskette.
In the next display the answer may be both, YES or NO.

Service 912C 6 16
In the above Diagnosis display you can highlight Read Identification Block. Press ENTER
and Identification Data appears on the screen.
In this display under item 1 you can see the ZF-article numbers of test programmes and
diagnosis box, under item 2 the article no. of diagrnosis box and under point 3 the article no.
of the test programmes. Item 5 indicates which type of ZF-transmission there is in the test
programme and item 6 that it is a programme specially made for Hydrema!
Item 5 and 6 are important when other programmes are added in the computer later on.
To shift to the next page, you can click on the key ▼ , the remaining points are blank.
Click on √, press ENTER and you return to the display Diagnosis.
Highlight Return to Menu, press ENTER and you return to the display WG110 product
menu.
Service 912C 6 17
Highlight Test Inputs - Outputs and press ENTER. (this is a programme testing the
different inputs and outputs of transmission, gear selector and steering box.
The first test in the programme is Stationary System Test.

Highlight the line and press ENTER
Service 912C 6 18
The first display is an information display indicating what to do when you want to run this
test.
Press ENTER.
Control of gear selector.
Gear selector DW-2 (is discontinued, it was earlier mounted on 900-machines)

Gear selector DW-3 (is mounted on Hydrema 912).
ERGO II gear selector (is mounted on Hydrema 912C).
Return to Menu
Highlight ERGO II gear selector and press ENTER.

Service 912C 6 19
In this display a ‘blue’ line indicates that the signal of the gear selector forward is being
controled.
The next display appears automatically.

Service 912C 6 20
The ‘blue’ line in this display indicates also here that the reverse signal is being controled.
If the gear selector is not set in the demanded direction, the following display appears:
Here the display indicates that there is no forward signal, and the gear selector is in
permanent neutral.
If the gear selector is set in the direction demanded, the test continues giving instructions.
Move the gear selectior into 1. gear.

Press ENTER.
Service 912C 6 21
The display is indicating:
B1 OK (“Speed sensor engine pump speed” (48))
B3 OK (“Speed sensor internal center speed” (47))
B2 signal permanent applied (“Speed sensor turbine” (21))
Press ENTER.
Gear selector in 2. gear.

Press ENTER.
Service 912C 6 22
B3 OK
B1 signal permanent applied
B2 signal permanent applied
Press ENTER.
The displays continue with the different gears and indicate how the different signals change.
When the gears have been controlled, the extra function is automatically controlled.
Service 912C 6 23
Hereafter a new display appears indicating that the extra function could not be activated.
Press ENTER.
1
The next display indicates the control of the pilot lamps.

Press ENTER.
In this display the reverse light is being controlled. Press ENTER and the clutches will be
controlled.
Service 912C 6 24
The clutches K1, K2, K3, K4, KV and KR are indicated automatically. After the control of
the clutches a list with the error messages appears on the display.
You can shift between the above two displays by clicking on the key ▼ or ▲ .
The list of error messages indicates the errors found on system check.
The condition of the clutches following is listed as the next items.
Press ENTER.
Service 912C 6 25
The display with the different gear selectors appears. Highlight Return to Menu, press
ENTER and you return to the menu programme Inputs - Outputs.
Highlight the next item Drive System Test and press ENTER.
Check engine speed

Start engine
Start the engine and press ENTER.

Service 912C 6 26
Press ENTER.
Press ENTER.
The cumputer is running a system check now and brings error information.
Service 912C 6 27
Here the engine has been started, but the machine was not driving. You can see on the
display that there are errors. The text on the display says:
Errors found on system check driving
Engine speed OK
Turbine speed okay

The display for the check of the turbine is not shown.
Signal speed mid-range gear train missing
Signal speed output EF4 missing
Press ENTER.
The drive system tes is finished now and you can highlight the next item Test Device nu.
and press ENTER.
Service 912C 6 28
The programme Test Device indicates on a digital display the various information from
earlier programmes. It is not necessary to enter this programme, but it is possible to ‘see’
here if for ex. a cable is disconnected.
The five items are:
Digital input & outputs

Speed engine &
Speed turbine
Digital input & output

Speed turbine &
Speed mid-range gear train
Digital input & output

Speed engine &
Load signal
Return to Menu
Highlight for ex. item 4 and press ENTER.
The display indicates the engine revolutions (rpm) and load (%).
Service 912C 6 29
The buttons have abbreviations. If you need the explanation click on the question mark ‘?’.
These buttons have the ‘same’ function as the ones on the ZF-check instrument of the ‘old’
machines 900.
Here you can shift between the pages up and down when you click on the keys ▼ and ▲ .
Leave Help facility with a click on √ or press ENTER .
Service 912C 6 30
When you have left the field Help facility you can click on one of the buttons and a little
window will appear in the existing display:
This window indicates with which one of the pins (no.) on the large plug on the control box
the button is connected with.
You can leave the little information window again with a click on √.
To leave the display press ENTER or click on √
To leave the test highlight Return to Menu and press ENTER..

Service 912C 6 31
You are now back in Test Inputs - Outputs.

Highlight:
Speeds, load sensors, oil sump, retarder temperatures

There is no retarder mounted on the Hydrema 912C.
Press ENTER.
The programme indicates the digital current values.
Highlight Oil sump, retarder temperatures and press ENTER

Service 912C 6 32
This display indicates the temperature of the transmission.
To return to the menu press ENTER.
Highlight Speeds and press ENTER.

Service 912C 6 33
In this display you can read the graph with information about the different revolution
sensors
Engine speed x 100 rpm

Turbine speed x 100 1/min
Mid-range gear train x 100 1/min
Output speed x 100 1/min
To leave the display press ENTER or click on √ and you return to the menu.
Hightlight Return to Menu, press ENTER and you return to the main menu Test Inputs -
Outputs.
Service 912C 6 34
The second last item in this test is:
Power outputs
Highlight the linie and press ENTER.
The display shows the different clutches being in active - in this case the manual 1. forward
gear.
To leave the display press ENTER.
Highlight Return to Menu and pres ENTER.

Service 912C 6 35
Now you are back in WG110 product menu which was the main menu in the test.
Highlight Vehicle Configuration and press ENTER.
In the programme with the configuration of the vehicle the following warning appears on the
display:
Control unit is not suitable for this function, if communication is interrupted on the
following step.
Press ENTER
Service 912C 6 36
In this programme the transmission is checked and adjusted automatically by the computer.
This programme must be run after every oil change and 50 hours’ service.
Begin with highlighting Indicate K1, K2, K3 and press ENTER.
Six information appear on the display. They can be copied and preserved on a diskette if
needed.
AEB pressure K1 -0.15 bar

AEB Zeit K1 -0.03 s

AEB Zeit K2 -0.05 s

AEB Zeit K3 -0.03 s
To return to the menu press ENTER.

Service 912C 6 37
Indicate AEB data K4, KV, KR
Press ENTER.

AEB Zeit K4 -0.03 s
AEB pressure KV -0.20 bar

AEB Zeit KV -0.06 s
AEB pressure KR -0.10 bar

AEB Zeit KR -0.00 s
Also these information can be copied or written down for later use (statistics).
As fitter one has no influence on these times and prints, as they will be changed when going
through the AEB programme.
Press ENTER.
Service 912C 6 38
Highlight the line Start AEB data logging now and press ENTER.
The first coming display in this test and adjustment programme is an information page..
To start check/adjustment press ENTER.

Service 912C 6 39
When the transmission is checked/adjusted, the above display appears. In the above case the
working temperature is not optimal and therefore, the message AEB data logging not
started yet. Starting conditions not fullfilled appears on the top line.
If the working temperature and the engine revolutions are highlighted in the middle of the
two lower graphs, the test programme will automatically check all the clutches, and then it is
possible again to enter the programmes Indicate K1, K2, K3 and Indicate AEB data K4,
KW, KR - and to preserve the new information on a diskette.
The ZF-Service telephone list is the last item in the main menu. This list contains the name
and telephone number of the German techniciens.
To leave the test programme click on the key X at the top on the right corner.
Service 912C 7 1
Fuses and relays:

The fuses are placed three different places.
Service 912C 7 2
Service 912C 7 3
Multitip.
Dumper body is placed in middle position:
Diode B16 off.

Diode B17 on ( light in diode ).
Body raised approx. 20 cm., still in middle position:
Diode B16 on ( light in diode and the alarm ”BODY RAISED” in display ).
When body is raised approx. 20 cm. it can be turned:

Diode B17 off when body is turned approx. 15 degrees.
Lowering the body with it turned to under approx. 20 cm.:
Diode B16 off.

Diode B17 off.
The body movement will now stop. Then for lowering the body You have to raise it to more
than 20 cm. above the frame. Then the light in diode B16 in on (diode becomes an signal).
Hereafter the body can be turned to middle position and then be fully lowered.
The solenoid valves V5 and V6 are ”only” putting in a limitation to the lowering function.
912 C
El - Diagram Circuit Diagram E - Schaltplan
Indhold Content Inhalt Side/Page/Seite

Generelt General Im allgemeinen 2
Diagramforklaring Diagram key Schaltplanklärung 2
Farvekode Colour key Farbe Kode 3
Centralenheder Main components Zentralkomponenten 4

placering placing positionerung
Sikringsgrupper Fuse boxes Sicherunggruppen 5
Komponentliste List of components Komponentenlisten 6
Diagram Circuit Diagram Schaltplan 9
912C
Udgave/Edition/Ausgabe uge/år Godkendt 50/02 LHA
1 2022290 1/15
GENERELT IN GENERAL
Diagrammet er opbygget som et nøglediagram, hvor strømkildene øverst, og stel nederst, The circuit diagram is built-up as a key chart. The power supply and ground at the top and
er ført igennem på alle siderne. Diagrammet er velegnet til fejlfinding, idet ledninger og bottom respectively are shown on all pages. This diagram is well suited for trouble
stikforbindelser er identificerbare. For eventuel montage, anvendes tegning på de respektive shooting, as wiring and connectors can be identified. For mountings use the drawing on the
ledningsnet. respective wiring.
(Symboler mv. refererer til følgende normer: IEC 117, 617, DIN 40719, 72552 og tegn. 413620) (The symbols etc. refer to the following standards: IEC 117, 617, DIN 40719, 72552 and
For nogle af hovedkomponenterne findes separate diagrammer. drawing 413620). Separate circuit diagrams are available for some of the main
components.
Diagramforklaring:
Der findes 3 sikringsgrupper på maskinen, alle placeret i kabinen. Circuit diagram key:
“GR1” placeret i forvæg højre side. The machine has 3 circuits, all placed in the cab:
“GR2” placeret under sideinstrumentpanelet højre side. ‘GR1’ placed in the front wall on the right side.
“GR3” placeret under sædet. ‘GR2’ placed under the side dashboard on the right side.
“KL-30” = 12 volt direkte fra batteriet, og “KL-15” = 12 volt over tændingsnøglen. ‘GR3’ placed under the seat.
“31” = stel. (placeret på udvalgte stelterminaler) ‘KL-30’ = 12V direct from the battery, ‘KL-15’ = 12V with the ignition key.
‘31’ = ground (placed on selected ground terminals).
Enhver betegnelse i diagrammet med bogstav og nr., har henvisning til komponentlisten.
Nederst på diagrammet er vist symboler for de aktuelle funktioner. Each part of the circuit diagram has a letter and a number referring to the component list.
Vær opmærksom på at den samme betegnelse på relæer og sikringer i diagrammet kan At the bottom of the diagram you can see the symbols for the functions.
forekomme flere gange, idet sikrings- og relænumrene for GR 1 og 2 er ens. Hvilken gruppe Please note that the designations for relays and fuses of the diagram may appear several
de tilhører kan ses øverst i diagrammet, eller på sikringsgruppe oversigten side 5. times, as the number of GR1 and 2 for the fuses and relays are identical. The diagram head
shows the group they belong to, or you can see it in the fuse box chart page 5.
Enhver ledning som findes på maskinen er ikke nødvendigvis at finde i diagrammet; men alle
samlinger i et givet kredsløb er illustreret med en -o- (bolle) for destinationen, f.eks “X8-3”, It is not given that you can find all wires of the machine in the diagram, but all connections
hvor X8 er betegnelse for multistikket, og 3 er ben nr. in a given circuit are illustrated by an -o- (small circle) for the destination, for example
‘X8-3’, X3 is the multiple connector and 3 is the pin no.
Henvisninger : Eks.Î X8-3 15 henvisning til multistik X8 ben 3, som findes på side 15.
12 K3 Í henviser til relæ K3 på side 12. Reference: Î X8-3|15 - Refers to multiple plug X8, current path 3, on page 15.
Ledningsmærkning: 12|K3 Í refers to relay K3 on page 12.
Eks. Ledningsdimension Wire Marking

Ledningsfarve( r ) Example:
Wire dimension
Ledningsmærkning Wire colour(s)
Destination Wire marking
0.75 Bk 5A (3) Destination
0.75 Bk 5A (3)
912C 2 2022290 /
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ALLGEMEIN
Der Schaltplan ist als Schlüsseldiagramm aufgebaut, mit den Stromquellen oben und der Masse
unten. Das Diagramm eignet sich gut zur Fehlersuche, da Leitungen und Stecker identifizierbar Ledningsfarver / Wire colours / Leitungsfarben:
sind. Bei eventueller Montage die Zeichnung auf dem jeweiligen Leitungsnetz verwenden.
(Die Symbole etc. beziehen sich auf folgende Normen: IEC 117, 617, DIN 40719, 72552 und
Zeichng. 413620). Für einige Hauptkomponenten gibt es gesonderte Diagramme.
Schaltplanerklärung: Farve Colour Farbe

Es gibt auf der Maschine 3 Sicherungsgruppen, alle in der Kabine angebracht: Bk Sort Black Schwarz
‘GR1’ in der Vorderwand, rechts
R Rød Red Rot
‘GR2’ unter dem Seitenbedienpult, rechts
‘GR3’ unter der Abdeckung des Bedienungshebel Y Gul Yellow Gelb
‘KL-30’ = 12V direkt von der Batterie, ‘KL-15’ = 12V über den Zündschlüssel Gn Grøn Green Grün
‘31’ = Masse (an bestimmten Masseterminalen angebracht) Bl Blå Blue Blau
G Grå Grey Grau
Alle Bezeichnungen mit Buchstabe und Nr. im Diagramm beziehen sich auf die W Hvid White Weiss
Komponentenliste. Bn Brun Brown Braun
Im Schaltplan, unten, sind die Symbole der jeweiligen Funktionen angegeben. O Orange Orange Orange
Bitte beachten, dass die Bezeichnungen der Relais und Sicherungen des Diagramms mehrmals V Violet Violet Violet
vorkommen können, da die Sicherungs- und Relais-Nummern für GR1 und 2 dieselben sind. Zu L Lys(e) Light Hell/Licht
welcher Gruppe sie gehören, ist aus dem Diagrammkopf ersichtlich, oder der
Sicherungsgruppen-Übersicht Seite 5.
Nicht alle Leitungen der Maschine sind im Diagramm angegeben, jedoch sind alle
Verbindungen innerhalb eines Stromkreises mit -o- (Kreis) für ihre Bestimmung angegeben, z.B.
‘X8-3’: X8 gibt den Multistecker an, 3 den Steckerstift.
Hinweis : Î X8-3|15 Hinweis auf Mehrfachstecker X8, Bein 3, auf Seite 15.
12|K3 Í verweist auf Relais K3 auf Seite 12.
Kabelnkennzeichnung:
Beispiel Kabelndimension
Kabelnfarbe(n)
Kabelnkennzeichnung
Destination
0.75 Bk 5A (3)
912C
Udgave/Edition/Ausgabe 1 uge/år
3 2022290 3/
15
Fig Betegnelse Description Bezeichnung Pa Note Fig Betegnelse Description Bezeichnung Pa Note
A CENTRALENH. CENTRAL UNITS ZENTRALEINH. E FORBRUGERE CONSUMER VERBRAUCHE
A1 Geardisplay Gear display Gangschaltdisplay 13 E1 Tågebaglys Rear fog light Nebelschluβleucht 9
A2 Gearvælger Gear selector Gangschalter 13 E3 Nærllys Dipped beam Abblendlicht 9 LH
A3 Instrumentdisplay Instrument display Instrumentendisplay 12 E4 Nærllys Dipped beam Abblendlicht 9 RH
A4 Sikringsgruppe 1 Fuse box 1 Sicherungsgruppe 1 all Page 5 E5 Fjernlys Main beam Fernlicht 9 LH
A5 Kombi kontakt Combiswitch Kombischalter 9 -10 -11 E6 Fjernlys Main beam Fernlicht 9 RH
A6 Styrebox, gear Gear control unit Kontr.einheit/Gänge 13 EST37 24V E8 Parkeringslys Parking light Standlicht 9 Front LH
A7 Sikringsgruppe 2 Fuse box 2 Sicherungsgruppe 2 5 Page 5 E9 Parkeringslys Parking light Standlicht 9 Front RH
E10 Baglys Rear light Rücklicht 9 LH
B GIVERE SENSOR GEBER E11 Baglys Rear light Rücklicht 9 RH
B1 Brændstofpumpe Fuel pump Kraftstoffpumpe 9 RPM E12 Markeringslys Marker light Markierungsleucht 9 Top LH
B2 Brændstof niveau Fuel level Kraftstoffstand 12 E13 Markeringslys Marker light Markierungsleucht 9 Top RH
B3 Kølevæske temp. Coolant temp. Kühlwassertemp 12 E14 Luftsæde Air seat Luftsitz 15 Option
B5 Bremsetryk Brake pressure Bremsdruck 12 min. E15 Rotorblink Warning beacon Rundumleuchte 10 Option
B6 Transm.-olietryk Transm. oil pressure Getriebeöldruck 12 min. E16 Rotorblink Warning beacon Rundumleuchte 10 Option
B7 Transm.-olietemp Transm. oil temp. Getriebeöltemp. 12 max. E17 Signalhorn Horn Hupe 10
B9 Styring, olietryk Steering oil pressure Lenkungsöldruck 12 min. E18 Magnetkobling Clutch Magnetkupplung 10 Kompressor
B10 Hydraul.olietemp. Hydraulic oil temp. Hydrauliköltemp. 12 max. Option E19 Radio Radio Radio 10
B11 Luftfilter vakuum air filter vacuum Luftfilter Vakuum 12 max. E20 Blinklys Direction indicator Blinker 11 Front RH
B13 Motorolietryk Engine oil pressure Motoröldruck 12 min. E21 Blinklys Direction indicator Blinker 11 Front LH
B14 Stoplyskontakt Brake light switch Bremslichtschalter 10 E22 Blinklys Direction indicator Blinker 11 Rear RH
B15 Hastighed Speed Geschwindigkeit 13 Km/h (X23) E23 Blinklys Direction indicator Blinker 11 Rear LH
B16 Induktivgiver Inductive sensor Induktivgeber 14 Tippet E24 Blinklys Direction indicator Blinker 11 Side RH
B17 Induktivgiver Inductive sensor Induktivgeber 14 multitip only E25 Blinklys Direction indicator Blinker 11 Side LH
B18 Temp. føler Freeze, switch Temperaturfühler 15 A/C E26 Arbejdlys Work lamp Arbeitsscheinwerf 11 LH Rear
B19 Trykføler høj tryk Pressure switch high Druckwächter Hoch 15 A/C E27 Arbejdslys Work lamp Arbeitsscheinwerf 11 RH Rear
B20 Trykføler høj lav Pressure switch low Druckwächt. Nieder 15 A/C E28 Arbejdslys Work lamp Arbeitsscheinwerf 11 LH Front
D DIODER DIODE DIODE E29 Arbejdslys Work lamp Arbeitsscheinwerf 11 RH Front
D1 Tipstyring Tip steering Kippsteuerung 14 multitip only E30 Arbejdlys Work lamp Arbeitsscheinwerf 11 Front
912C 2022290 6/
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E31 Arbejdlys Work lamp Arbeitsscheinwerfer 11 Front K6 Tidsrelæ,transmi Timer, transmission Zeitrelais, Getriebe 13 Gear Gr. 1-
E32 Arbejdslys Work lamp Arbeitsscheinwerfer 11 Rear K6 Air condition Air conditioning Aircondition 15
E33 Arbejdslys Work lamp Arbeitsscheinwerfer 11 Rear K7 Transmission Transmission Getriebe 13 Gear Gr. 1 -
E35 Omdrejningstælle Tachometer Tachometer 12 Rpm K9 Dumperkasse Dumper body Dumpermulde 14 Multitip only
E36 Motor forvarmer Engine preheater Motor-orvärmer 12 K11 Effektrelæ Power relay Leistungsrelais 9 Gr.1-
E37 Baklys Rear light Rücklicht 13 K11 Startsignal Trans Starting signal Startsignal Transm. 9 Gr. 3 12V
E39 Bremselys Brake light Bremslicht 10 LH K12 Baklys Reversing light Rückfahrlicht 13 Gr. 3 24V
E40 Bremselys Brake light Bremslicht 10 RH K13 Transmissionsfej Transmission error Getriebefehler 13 Gr. 3 24V
E42 Sædevarme Seat heating Sitzheizung 14 Option K14 Intervalvisker Interval Wiper Intervall Wisher 10
E43 Spejlvarme Mirror heating Spiegel mit heizung 15 K15 Advarselsblink Hazard lights Warnblinkanlage 11 Gr. 1
K16 Forvarmer Preheater Vorwärmer 12 Engine
F SIKRINGER FUSES SICHERUNGEN M MOTORER ENGINES MOTOREN
F1→ Se side 5 See page 5 Siehe Seite 5 5 Gr. 1+2+3 M1 Sprinkler Washer Scheibenwischanl. 10 Front
M2 Forrudevisker Wiper, wind screen Wischer, vorn 10
G FORSYNINGER SUPPLIES SPEISUNG M3 Blæsermotor Fan motor Gebläsemotor 10 A/C
G1 Batteri Battery Batterie 9 M4 Blæsermotor Fan motor Gebläsemotor 10
G2 Generator Alternator Lichtmaschine 9 M5 Bagrudevisker Wiper, rear Wischer, hinten 10
G3 DC/DC converter DC/DC converter DC/DC Konverter 9 12V / 24V M6 Sprinkler Washer Scheibenwaschanl. 10 Rear
M7 Startmotor Starter Anlasser 9
H KONTROLLYS PILOT LAMPS KONTROLLAMP
R MODSTANDE RESISTORS WIDERSTÄNDE
K RELÆER RELAYS RELAIS
K1 Motor start Engine start Motor anlassen 9 Gr. 1 S KONTAKTER SWITCHES SCHALTER
K2 Bremselys Brake light Bremslicht 10 S1 Hovedafbryder Main switch Hauptschalter 9
K2 Arbejdslys Work lamp Arbeitsscheinwerfer 11 LH, RH Gr. 2 S2 Startnøgle Ignition key Zündschlüssel 9
K3 Arbejdslys Work lamp Arbeitsscheinwerfer 11 Front, rear Gr. S4 Tågebaglys Rear fog light Nebelrücklicht 9
K3 Tågebaglys Rear fog light Nebelrücklicht 9 Gr. 1 S5 Lyskontakt Light switch Lichtschalter 9
K4 Nærlys Dipped beam Abblendlicht 11 Gr. 1 S6 Kombikontakt Combi switch Kombischalter 9 -10 -11
K5 Fjernlys Main beam Fernlicht 11 Gr. 1 S7 Rotorblink Warning beacon Rundumleuchte 10
S8 Horn Horn Hupe 10 Side panel
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S9 Sprinkler Washer Scheibenwaschanl. 10 Side panel X4 Gearvælger Gear selector Gangschalter 13 4-pol
S10 Visker bagrude Wiper, rear Wischer, hinten 10 Side panel X5 Bagrudevisker Wiper, rear Wischer, hinten 10 4-pol
S12 Blæsekontakt Fan switch Gebläseschalter 10 X6 El - stikdåse Socket outlet Steckdose 14
S15 Advarselsblink Hazard lights Warnblinkanlage 11 X7 Transmission Transmission Getriebe 12 -13 18- pol
S17 Arbejdslys Work lamp Arbeitsscheinwerfer 11 X8 Motor og lys Engine and light Motor und Licht 9 -12 18- pol
S18 Arbejdslys Work lamp Arbeitsscheinwerfer 11 X9 Motor Engine Motor 12 9-pol
S19 Arbejdslys Work lamp Arbeitsscheinwerfer 11 X10 Gearvælger Gear selector Gangschalter 13
S20 Arbejdslys Work lamp Arbeitsscheinwerfer 11 X11 Instrumentdispla Instrumentdisplay Instrumentendisplay 12 15-pol
S21 Parkeringsbrems Parking brake Handbremse 12 X12 Instrumentdispla Instrumentdisplay Instrumentendisplay 12 9-pol
S22 Transm.automati Transm. automatics Getriebeautomatik 13 on / off X13 Instrumentdispla Instrumentdisplay Instrumentendisplay 12 6-pol
S24 Loftslys Cabin light Kabinenlicht 14 X14 Diagnose,transm. Diagnosis, transm. Diagnose, Getriebe 12 4-pol
S25 Pendellås Pendling lock Pendelverriegelung 14 Option X15 Styreboks, Steering gearbox Schaltgetriebe 12 68-pol
S26 Sædevarme Seat heating Sitzheizung 15 X16 Sideinstrumentpa Side dash board Seitenarmaturbrett 9 -10 11-pol
S27 Spejlvarme Mirror heating Spiegel mit 15 X17 Armlæn Arm rest Armlehne 13
S28 Diff.spærre Differential lock Differentialspærre 14 X18 Temp.føler Freeze, switch Temperaturfüler 13 2-pol
S29 Arbejds-baklys Work-Rear lamp Arbeitsscheinw.Rüc 13 X19 Transm. turbine Transm. turbine Getriebeturbine 13 2-pol
S30 Option Option Option 14 X20 Transm gear. Transmission gear Getriebegang 13 2-pol
V MAGNETVEN SOLENOIDVALV MAGNETVENTI X21 Tr.motoromdr. Transm.motor revol. Getriebemotorumdr. 13 2-pol
V1 Brændstofpumpe Fuel injection pump Kraftstofpumpe 9 “stop” X22 Transm.ventiler Transmission valves Getriebeventile 13 16-pol
V3 Parkeringsbrems Parking brake Handbremse 12 X23 Transm.hastighe Transm. speed sens. Geschwind Geber 13 3-pol
V5 Dumperkasse tip Dumper body / tip Mulde/Kippfunktion 14 multitip only X25 Samling Connecting Verbindung 14 16-pol
V6 Dumperkas. Dumper body/turn Mulde/Drehfunktion 14 multitip only X27 Geardisplay Gear display Display / Gänge 13 4-pol
V8 Pendellås Pendling lock Pendelverriegelung 14 Option X28 Geardisplay Gear display Display / Gänge 13 4-pol
V9 Diff.spærre Differential lock Differentialspærre 14 X29 Multitip Multitip Multitip 14
V10 Hydr.- lås Hydr. - lock Hydr.- schloß 14 X30 Multitip Multitip Multitip 14
V11 Option Option Option 14 XK Multikontakt Multi switch Multischalter 9.1 .11
X MULTISTIK MULTIPLUGS MULTISTECKER XL Multikontakt Multi switch Multischalter 9.1 .11
X1 Forrudevisker Wiper, wind screen Wischer, vorn 10 4-pol
X2 Blæsermotor Fan motor Gebläsemotor 10 4-pol
X3 Gearvælger Gear selector Gangschalter 13 4-pol
912C 2022290 /
SERVICE 912C 8 1
INSTRUMENT PANEL
Alarms 2
Display keys 7
Operating window 8
Main menu 8
Service menu 9
Authorised service 13
Set-up menu 14
Hire menu 16
Start alarm 17
Menu structure 20
Service times 21
SERVICE 912C 8 2
INSTRUMENT PANEL
1. Indicator lamp:
Fuel level
The lamp lights up if the fuel level in the tank is low (around 15 litres).
Indicator lamp: Yellow
Audible alarm: None
Logging: None
Warning text: “ LOW FUEL LEVEL “ appearing for 5 seconds every 30 seconds
(60 sec. after starting up )
Alarm priority: 15. The alarm must only appear in the operating window.
2. Indicator lamp:
Hydraulic oil temperature.
The lamp lights up if the temperature of the hydraulic oil is too high. The maximum
permissible oil temperature is 93o C.
Indicator lamp: Red
Audible alarm: No delay, intermittent note every 5 seconds.
Logging: The year, date and time of the alarm are logged after 60 seconds.
Warning text: “ HYDRAULIC OIL TEMPERATURE TOO HIGH”, non-flashing
Alarm priority: 11
SERVICE 912C 8 3
3. Control pump indicator lamp:
The lamp lights up if the oil supply from the control pump fails.
The lamp lights up when the ignition key is turned during start-up. When the engine starts
and the pump is in operation, the lamp should extinguish.
Indicator lamp: Red
Audible alarm: 1 second delay, intermittent note every half second.
Warning text: STOP! "LOSS OF CONTROL PRESSURE", non-flashing.
Alarm priority: 2
If the control pump lamp lights up, the machine must be
stopped immediately.
WARNING
4. Indicator lamp:
Transmission oil temperature. NB!! NOT MODELS 900MPV OR WL
The lamp lights up if the temperature of the transmission oil is too high.
Indicator lamp: Red
Audible alarm: No delay, intermittent note every 5 seconds.
Logging: The year, date and time of the alarm are logged after 60 seconds..
Warning text: “TRANSMISSION OIL TEMPERATURE TOO HIGH", non-flashing
Alarm priority: 10
5. Indicator lamp:
Transmission oil pressure. NB!! NOT MODELS 900MPV OR WL
The lamp lights up if the pressure of the transmission oil is too high.
Indicator lamp: Red
Warning text: “TRANSMISSION OIL PRESSURE TOO LOW “, non-flashing
Alarm priority: 6
6. Indicator lamp:
Brake pressure
The lamp lights up if the pressure in the brake system is too low. The machine must not be
operated if this lamp is on.
Indicator lamp: Red
Logging: The year, date and time of the alarm are logged after 60 seconds..
Warning text: STOP! "BRAKE PRESSURE TOO LOW“, non-flashing
Alarm priority: 3
SERVICE 912C 8 4
7. Indicator lamp:
Handbrake.
The lamp lights up when the handbrake is on. If the lamp is on while the machine is in
movement, an audible alarm will sound and a warning text will appear on the display.
Indicator lamp: Red
Audible alarm: Alarm with no delay if speed exceeds 0.5 km/h.
Logging: None.
Warning text: “HANDBRAKE ON”, non-flashing
Alarm priority: 14
8. Indicator lamp:
Flashing turn indicator, trailer.
This lamp flashes if an extra flashing indicator has been connected to the seven-pole outlet.
(Optional).
9. Indicator lamp:
Flashing turn indicator.
10. Indicator lamp:

Charging.
This lamp lights up if the generator is failing to charge the battery correctly. The lamp lights
up when the ignition key is turned and should extinguish as the engine revolutions increase.
Indicator lamp: Red
Audible alarm: None
Warning text: None
Alarm priority:
11. Indicator lamp:

Main beam warning lamp.
12. Indicator lamp:

Engine oil pressure.
This lamp lights up when the ignition key is turned, or if the oil pressure is too low.
If the lamp lights, stop the engine immediately and investigate the cause.
Indicator lamp: Red
Audible alarm: No delay, intermittent note every half second.
Logging: The year, date and time are logged after 2 seconds.
Warning text: STOP ! “ENGINE OIL PRESSURE TOO LOW”, non-flashing
Alarm priority: 1
SERVICE 912C 8 5
13. Indicator lamp:

Engine coolant temperature.
This lamp lights up if the engine coolant temperature is too high. The maximum permissible
temperature is 103o C.
Indicator lamp: Red.
Audible alarm: No delay, intermittent note every half second.
Logging: The year, date and time are logged after 2 seconds.
Warning text: STOP ! “ COOLANT TEMPERATURE TOO HIGH”, non-flashing
Alarm priority: 9
14. Indicator lamp:

Engine coolant level.
(Not mounted as standard.)
15. Indicator lamp:

Pre-heating.
This lamp lights up when the ignition key is turned to position 2 to pre-heat the engine.
The engine is started after about 15 seconds.
Indicator lamp: Yellow.
Audible alarm: None.
Logging : None.
Warning text: After 7.00 pm, the text "PRE-HEATING. WAIT 15 SECONDS."
will appear for 5 seconds, followed by “START ENGINE” .
16. Indicator lamp:

Air filter, engine.
This lamp lights up if the air filter is blocked. If the lamp lights while the engine is in
operation, the filter should be changed or cleaned.
Indicator lamp: Yellow.
Audible alarm: Alarm after 15 seconds, each time the engine is started. Alarm duration,
10 seconds. The alarm will not sound again until the engine is re-started.
Logging: The year, date and time of the first alarm are logged after 15 seconds.
Warning text: The warning text "AIR FILTER BLOCKED" appears for 10 seconds
simultaneously with the audible alarm.
Alarm priority: 12
SERVICE 912C 8 6
17 Hydr. Filter: ( Optional)
(not mounted as standard)
Transmission fault:
Indicator lamp: None.

Logging: The alarm is dependant on the engine running. The year, date and
time of the alarm are logged after 30 seconds.
Warning text: ”TRANSMISSION FAULT” (with symbol), dependant on engine
running, non-flashing. May be removed by pressing <ESC>.
(If there is a steady signal of 0V, followed by 12V, the text will be
displayed again.)
Priority 5
Stabilizer alarm NB !! 906C/908C only.

Audible alarm: The alarm will sound if the engine is running. No delay.
Logging: None.
Warning text: "STABILIZER ALARM”.
Alarm priority: 7
Dumper bucket raised NB!! 912/912C only

Logging: None.
Warning text: “ DUMPER BUCKET RAISED ”, flashing.
Alarm priority: 8
SERVICE 912C 8 7
DISPLAY KEYS
1) ▲ This key is used to move the display cursor upwards in a menu, or to adjust numbers
upwards when setting the time and date.
2) ▼ This key is used to move the display cursor downwards in a menu, or to adjust
numbers
downwards when setting the time and date.
3) ◄ This key is used to move the display cursor to the left.
4) ► This key is used to delete service menu items, or to move the cursor to the
right.
1) The RED – ”ESC” key is used to return to the operating window from any
other menu.
2) The GREEN – ”ENTER” key is used to select menus and menu items, and to
confirm new settings.
SERVICE 912C 8 8
OPERATING WINDOW.
The operating window is equipped with speedometer, odometer, and digital clock.
MAIN MENU
Pressing the "ENTER" key changes the display to the main menu.
RESET 10 hr CHECK
► SET CLOCK
SERVICE MENU
The cursor can be moved between the various menu items using the ▲ and ▼ keys. A menu
item is selected by pressing "ENTER".
RESET 10 hr CHECK
When this menu item is selected by pressing the ENTER key, the time at which the next 10-
hour check will be due will be displayed. It is also possible to reset the timer here for all 10-
hour checks.
If daily checks are carried out, it is a good idea to reset the 10-hour check timer following
this, so that no further 10-hour check warnings are produced for the rest of the day.
Resetting the timer is achieved by depressing the ► key for more than half a second. If
resetting is not required, press "ESC".
SERVICE 912C 8 9
SET CLOCK
You can set the current time and date by selecting this menu item with the "ENTER" key.
TIME 14.27.22
(Hours, minutes and seconds)
DATE 96.05.28
(Year, month and date)
Cursor – Can be moved using the ◄ ► keys. The individual numbers are adjusted with the
▲ ▼ keys.
The clock stops while the numbers are being adjusted. It may be re-started by pressing
"ENTER".
When the settings are correct, they may be confirmed by pressing "ENTER". If no alteration
is desired, pressing "ESC" will return the user to the operating window.
It is recommended that the time and date are always correctly set, as this is of importance for
the instrument readings.
NOTE: The clock is stopped for as long as the "set clock" window is displayed.
SERVICE MENU.
► TIME AND DISTANCE LOG
HYDR. OIL TEMP.
When this menu is selected, a number of menu items are displayed that enable access to
important service information.
The cursor can be moved between the various menu items using the ▲ and ▼ keys. A menu
item is selected by pressing "ENTER".
The machine's records are displayed in the first line, "TIME AND DISTANCE LOG".
E.g. hours date km.

01205h 96.11.05 01996
This tells us that the machine has been in operation for 1,205 hours since 5/11/96, and has
travelled 1,996 kilometres in that period of time.
This information is logged every 500 hours, starting with 0-500h, 500-1,000h, and up to
20,000h.
SERVICE 912C 8 10
The current time interval is displayed on the uppermost line.

The information here is stored in the instrument's memory and cannot be deleted or altered.
The other items on the service menu are alarm log lists, covering the following alarms:
- Hydraulic oil temperature (93 degrees C).
- Control pressure (4 bar.)
- Transmission oil temperature (120 degrees C).
- Transmission oil pressure (10 bar.)
- Brake charging pressure (28 bar.)
- Generator charging check.
- Engine oil pressure.
- Coolant temperature (103 degree C).
- Coolant level (if indicated).
- Engine air filter (750 mb).
- Hydraulic filter blocked.
- Transmission fault.
The 10 most recent alarms in each category are logged by their date and time of occurrence.
(Older alarms are automatically deleted.)
No alarms are logged for 10 seconds after the "engine running" signals are registered as
"OK". (Typically when starting up, and whenever the ignition key has passed the OFF
position.)
ENGINE RUNNING SIGNALS
3 signals indicate "engine running": engine oil pressure, control pressure and the W signal
(engine frequency). If any one of these is "OK", the engine will be registered as "running".
Other alarms will then be logged as necessary, and the instrument clock will begin to run.
If the same alarm occurs repeatedly, logging will only be performed every 10 minutes
(according to the display clock).
If an alarm is due to a fault, e.g. in a sensor, the alarm logs for the function in question should
be deleted when the fault has been repaired.
DELETING ALARM LOGS
Select this function from the service menu by pressing "ENTER".

Depress arrow right for one second to display the personal identification number (PIN code)
window. Enter the relevant PIN code (see service information, points 1-19), and then press
"ENTER". This will delete all alarm logs for the function in question, whereupon the display
will return to the service menu.
SERVICE 912C 8 11
ALARM WINDOW
STOP
COOLANT
TEMPERATURE
TOO HIGH
Faults in important functions will result in an audible alarm being sounded and a warning text
appearing on the display.
The warning text, together with the relevant indicator lamp, will reveal the location of the
fault.
WARNING
Always obey the advice shown on the display. Continuing to operate the machine after a
STOP warning has been given may involve danger to the life of the operator or risk serious
damage to the machine.
The alarm will cease automatically when the fault has been repaired and the machine has been
started up again.
SERVICE CHECK WINDOW
The service icon will appear in the upper left corner of the operating window when the
machine's maintenance chart indicates that a service check is due. "ENTER" is then pressed to
call up the service menu, which indicates the maintenance tasks that are required.
SERVICE 912C 8 12
At 10-HOUR SERVICE CHECKS, the following checklist will be displayed:
Check engine oil level.

Check transmission oil level.
Check coolant level.
10-hour lubrication.
When the maintenance task indicated by the cursor has been carried out, the task can be
deleted from the checklist using ►. The cursor can then moved to the next points on the list
using ▼ or ▲, and these tasks are then deleted in similar fashion when the service check has
been performed.
When the entire list has been deleted, the service icon will disappear and the display will
return to the operating window.
If it is not possible to carry out the service check immediately, the required tasks may be
viewed by pressing "ENTER", returning to the operating window via the "ESC" key. The
service icon will in this case remain in the operating window.
It is possible to delete all of the items in the 10-hour service check window simultaneously.
See "Reset 10-hour check".
Check hydraulic oil level.

50-hours lubrication.
Check tyre pressure.
Check tyre pressure.

Check oil level in axles.
200-hour lubrication.
NOTE!
The first items in a 50-hour check will typically be the checklist items from a 10-hour check,
just as the first items in a 200-hour check will typically be from the 50-hour check, etc.
SERVICE 912C 8 13
AUTHORISED SERVICE.
The service icon, accompanied by a telephone, will appear in the operating window when the
machine's maintenance chart indicates that an authorised service is due.
When this icon appears, contact authorised service personnel to service the machine. The
"authorised service" icon will remain in the operating window until the service has been
carried out.
The "contact service personnel" icon will also appear as the final item on a 50-hour service
check menu when 50 hours of operation have been logged, as well as the last item on a 200-
hour service check menu. The icon will thereafter appear every 1,000 hours.
DELETING THE AUTHORISED SERVICE ICON
When the machine has been serviced, the "authorised service" icon may be deleted by the
following procedure: Press arrow right for one second to change the display to the PIN code
window. Enter the correct PIN code and press ENTER. The icon will then disappear.
SERVICE 912C 8 14
SET-UP MENU.
Under this menu, you can check or alter the display language, set speed factors, and check
the machine no. and type.
To enter the set-up menu:

Call up the main menu. Press arrow left for at least 5 seconds, and then press arrow up at the
same time. Enter the correct PIN code. You can now choose between the three following
menus.
NB! Do not alter the display language unless there is a good reason to do so.
Speed factors have a default setting based on a factor expressed as a percentage of vehicle
speed, and a level of 1 or 1/4, which gives the actual speed using the standard tyre set. If a
tyre set with a significantly different rolling circumference or other special features has been
fitted, it may be necessary to adjust the speedometer accordingly.
Adjust speed factor

Speed Factor
XX % Y
906B/908B XX = 113% and Y = 1

912 XX = 100% and Y = 1/4
912C XX = 100% and Y = 1/4
900MPV XX = 67% and Y = 1/4
Lift calibration is a special feature of the Hydrema 900 MPV. The position of the rear
lift is shown in the lower left-hand corner of the instrument display, above the trip
counter.
A variable linear resistor is located by the lift which must be calibrated when it is replaced.
1.
Lift at min. pos. - The lift is lowered to the ground.
- Press ”ENTER”
00%
2. Lift at max. pos.

- The lift is raised to its maximum position.
- Press ”ENTER”
99%
3. Press "ENTER" to accept settings.
SERVICE 912C 8 15
Service times, transmission:

1 = Power Shift transmission, applies to the 900B and 912
0 = Hydrostatic transmission, applies to the 900MPV and WL
If "0" is selected, no service check reminders will be displayed.

If "1" is selected, service check reminders will appear for the 50-hour and 1,000-hour checks.
DISPLAY CONTRAST
Display contrast can be adjusted as desired. The icon for contrast adjustment is located in the
lower right-hand corner of the operating window.
The screen image can be made darker by repeatedly pressing the ▲ key.
The screen image can be made lighter by repeatedly pressing the ▼ key.
The display contrast can be adjusted whenever the operating window is active.
The instrument possesses an in-built thermistor which regulates the display contrast in
relation to the temperature. Despite this, the default screen contrast may sometimes seem
inadequate, particularly in the first 5-10 minutes after start-up in sub-zero conditions. The
main reason for this is that the display numbers, etc., change more slowly at low
temperatures.
TRIP COUNTER
The trip counter enables the number of hours spent and kilometres travelled in relation to a
particular job to be directly displayed. The trip counter may be activated and deactivated via
the main menu. When the trip counter is on, it may be reset using the "ESC" key in the
operating window. The trip counter is automatically reset when deactivated. When the trip
counter is activated, the operating window is altered as shown below.
28.2 km/h
000.0
00.00 18.53 1853.0 km
The trip counter can count up to 999.9 kilometres or hours, whether the engine is running or
not.
SERVICE 912C 8 16
HIRE MENU
The hire menu makes it possible for the hire firm to obtain information regarding hours in
operation, distance travelled and alarms for each vehicle hire. In this first version, the
information appears on the display.
Selecting "HIRE MENU" with the "ENTER" key from the main menu produces a new
window containing the hire menu.
HIRE MENU
⎝ NEW JOB
INTERRUPT JOB
JOB RECORD
If "new job" is selected, a window appears in which the customer code can be entered. The
code is then confirmed by pressing "ENTER".
START NEW JOB

⎝ YES (Delete current data and initiate new record.)
NO (Delete current data but do not initiate new record.)
If "NEW JOB" is selected, the following information will begin to be recorded:

Number of hours the engine is running
Number of kilometres travelled
Hours and kilometres per day
List of alarms logged in this period (the 10 most recent)
If "INTERRUPT JOB" is selected, a window will appear in which the customer code may be
entered. Pressing "ENTER" after keying in the correct code will interrupt the data recording,
and the display will then return to the operating window.
If "JOB RECORD" is selected, a window will appear in which the customer code may be
entered. The following window is then displayed:
Machine no.:
Period: xx.xx.xx ∏ xx.xx.xx
Hours to date: xxxx arrow ► to move to next window
Km to date: xxxx
Hours per day:

arrow ▼ or ▲ to select day for alarm list.
24.02.97 7.06 hours
arrow ◄ back to previous window
25.02.97 5.35 hours
arrow ► select alarm list
SERVICE 912C 8 17
Alarm list
arrow ◄ back to previous window
arrow ▼ or ▲ to move through the list
”ESC” to return to main menu
START ALARM.
The start alarm produces a warning text on the display and an audible alarm if the machine is
started without entering the customer code. No active ignition disabling is available in this
version, but an alarm is produced to indicate unauthorised use of the machine.
The start alarm can be activated or deactivated from the main menu by the customer, so that it
can be disabled during the working day and then activated when the machine is left
unsupervised.
If the start alarm is activated, the following window will appear as soon as the ignition key is
turned:
START CODE
0 0 0 0
If the correct start code is entered, the normal operating window will appear. If, however, an
attempt is made to operate the machine without entering the start code, the following flashing
warning will appear, accompanied by an audible alarm consisting of a tone repeated once
every second, with no delay.
STOP!
UNAUTHORISED OPERATION
For servicing purposes, in cases where service personnel may not be aware of the customer
code, the alarm may be shut off by pressing arrow ◄ for 5 seconds, followed by arrow ▲.
This will silence the alarm and return the display to the operating window.
SERVICE 912C 8 18
DISABLING THE START ALARM
1) Press arrow left for 5 seconds.

2) Press arrow up and arrow left simultaneously (the alarm is turned off).
3) The operating window appears.
4) Press the green "ENTER" key.
5) The main menu appears.
6) Repeat points 1 and 2.
7) The PIN code window (0 0 0 0 ) appears.
8) Enter the correct PIN code. (See service information, points 1-19.)
10) The set-up menu appears.
11) Press arrow down until "CUSTOMER CODE" appears on the display.
13) The start code window ( 0 0 0 0 ) appears.
14) Enter a code, e.g. 1 1 1 1.
17) Press the red "ESC" key.
21) Press arrow down until the display pointer (>) indicates "START ALARM > ON".
22) Press arrow right.
23) Enter the same start code as at point 14, e.g. 1 1 1 1.
25) The start alarm is now OFF.
If the start alarm (customer code) has not been changed from 0 0 0 0, the alarm may be shut
down using the following procedure:
1) Turn on the ignition.

2) The customer code window, 0 0 0 0, appears.
7) Press ▼ until ”START ALARM >ON OFF” is selected.
8) Press ►.
9) Start alarm 0 0 0 0 appears.
12) The start alarm (customer code) is now OFF.
SERVICE 912C 8 19
ENTERING A START ALARM CODE (SAME AS CUSTOMER CODE)

3) Press arrow down until START ALARM ON > OFF is selected.
4) Press arrow left.
6) Turn off the ignition.
7) Turn the ignition on again.
8) The start code window, with 0 0 0 0, appears on the display.
9) Press arrow left for at least 5 seconds.
10) Press arrow up and arrow left simultaneously (the alarm is turned off).
14) Press arrow left for at least 5 seconds.
15) Press arrow up and arrow left simultaneously.
16) The PIN code window ( 0 0 0 0 ) appears.
17) Enter a valid PIN code (see service information, points 1-19)
20) Press arrow down until "CUSTOMER CODE" appears on the display.
22) The start code window, reading 0 0 0 0, appears.
23) Enter a customer code (customer's own choice).
26) Press the red "ESC" key.
28) Turn off the ignition.
29) Turn on the ignition again.
30) To check, enter the correct start (customer) code as specified by the customer under
point 23.
33) The customer code has now been entered and checked.
SERVICE 912C 8 20
SERVICE 912C 8 21
SERVICE TIMES
HOURS TEXT
10 Check coolant level
10 Check engine oil level
10 Check transmission oil level
10 10-hour lubrication - see instruction manual
50 Check hydraulic oil level
50 Check tyre pressure
200 Check oil levels in axles and hubs - see instruction manual
200 Check battery fluid status
200 Empty fuel system water separator
400 Change engine oil - for oil type, see instruction manual
400 Change engine oil filter
400 Change fuel filter
400 Change hydraulic filter
400 Change air filter
1000 Change oil in axles and hubs
1000 Change transmission oil
1000 Change transmission oil filter
2000 Chnage hydraulic oil
2000 Change coolant
First 50 hours 50-HOURS AUT. SERVICE
First 200 hours 200-HOURS AUT. SERVICE
Every 1,000 hours 1,000-HOURS AUT. SERVICE
May be deselected in the set-up menu

Service 912C 9 0
REPAIR
MANUAL
FOR
HYDREMA 912C
DUMP TRUCK
FRONT AXLE
Service 912C 10 0
REPAIR
MANUAL
FOR
HYDREMA 912C
DUMP TRUCK
REAR AXLE
Service 912C 11 1
Service 912C 11 2
Service 912C 11 3
Service 912C 11 4
Service 912C 11 5
Service 912C 11 6
Service 912C 11 7
Service 912C 11 8
Service 912C 11 9
Service 912C 11 10
Service 912C 11 11
Service 912C 11 12
Service 912C 11 13
Service 912C 11 14
Service 912C 11 15
SERVICE HYDREMA 12 1
FUNCTION OF THE AIR CONDITIONER (A/C)
In air conditioners the coolant (R134a) circulates under pressure through these five main
components: Compressor, condenser, liquid tank (dry filter), expansion valve and vaporizer.
The pressure, temperature and coolant form (liquid/gas) constantly change in these
components.
- Compressor. Irrespective of type or make, the compressor works as system pump by

circulating the coolant and increasing the coolant pressure. The compressor is fitted
with a magnetic coupling which controls the operation cycle and which are normally
driven by a belt from one of the engine pulleys. When the system demands more
cooling, the magnetic coupling is activated and the compressor begins to run. It sucks
the cold, gaseous coolant in from the vaporizer, increases the gas pressure by
compression and presses it on to the condenser. Liquid coolant must not enter the
compressor.
- Condenser. The condenser is normally mounted in front of the water cooler of the
vehicle or in a separate condenser unit. The warm, gaseous coolant from the
compressor flows into the top connection of the condenser, and on its way through
the pipes emits heat to the surrounding air, which is blown through the condenser.
The coolant becomes condensed and changes into a liquid form. In a system driven
under normal temperature conditions, the top two thirds of the condenser contain
gaseous coolant and the bottom third contains liquid coolant. The warm liquid coolant
being under high pressure flows from the condenser to the liquid tank (the dry filter).
- Liquid tank (dry filter). The liquid tank is used in most systems. The tank is either
mounted on the outlet pipe of the condenser or somewhere on the hose/pipeline
between the condenser and expansion valve. It consists of a tank that contains a
particle filter and a moisture-absorbing unit. Most liquid tanks are also fitted with a
gauge indicating whether the system is sufficiently filled with coolant. The liquid
coolant from the condenser is stored in the tank until needed in the vaporizer. The
demand for coolant in the vaporizer depends on the heat level and the setting of the
temperature sensor.
The liquid tank contains a moisture-absorbing unit and a particle filter that filters out
impurities. It is very important that moisture and impurities are filtered out as they can
damage the expansion valve, resulting in a compressor breakdown. The liquid
coolant flows under high pressure from the liquid tank.
- Expansion valve. The liquid coolant flows into the expansion valve under high
pressure. When the coolant flows through the expansion valve, it is forced through a
constriction and is ”sprayed” into the vaporizer. This creates a pressure reduction and
the coolant temperature drops.
- Vaporizer. Like the condenser, the vaporizer is constructed of pipes with thin slats. It
receives the liquid coolant with low pressure from the expansion valve. When the cold
coolant passes through the vaporizer, the heat from the air that flows through the
vaporizer is moved to the colder coolant. When a sufficient amount of heat is applied
to the coolant, the coolant changes and becomes gaseous again under low pressure.
The expansion valve releases a precise amount of coolant in order to achieve the
greatest possible heat exchange and to change the coolant to gas before it reaches
the vaporizer outlet and is sucked into the compressor again.
COOLANT CIRCUIT
Vaporizer
Expansion valve
Low-pressure
liquid
Low-pressure
gas
Blower
Compressor
Low- High-
pressure pressure
liquid liquid
Condenser
Liquid tank (dry filter)

Instructions to be followed in connection with service/repair on air conditioners
1. Service/repairs or other procedures involving the coolant circuit or devices that

influence the circuit function may only be performed by trained personnel.
2. The materials and construction must be chosen so that unintended spillage of

coolant through leakage, hose-burst or other system errors are avoided.
3. All systems must be fitted with a sign indicating the type and the capacity of
coolant needed in the system. Vehicles produced after 01/01.1989 (this applies
to Sweden) must also have an operation and protection manual.
4. Defects that can cause or result in spillage must be repaired immediately. The
filling or refilling of coolant must not take place before the system has been
checked by trained personnel and defects have been repaired.
When mounting a new compressor or when changing its oil, use 0.1 ltr. Elf PLANETELF ACD
46 – Hydrema article number 7800039. Fill the oil through the pressure pipe from the
compressor.
A thermostat – Hydrema article number 7500060 – is mounted on the top of the condenser.
To change the thermostat, dismount the condenser (drain the system) and remove the top
cap, so there is access to the thermostat sensor. This sensor must be mounted in a distance
of 155 mm from the edge of the condenser where the heat tap is fitted. Bend the sensor to an
angle of 90 degrees with a length of 90 mm and fit it from above in the middle of the
condenser width between the slats.
If the cab temperature is less than 17ºC, the compressor will not start.
Pressure sensors for high pressure (green) and low pressure (black) can be changed without
draining the system.
Capacities
926C/928C 1400 g
906C/908C 1400 g
906B/908B 1400 g
912 Dumptruck 1000 g
912C Dumptruck 1000g
900 MPV 1000 g
910 MCV 900 g
910 MCV-2 1000g

System pressure
High pressure side: 10 bar

Low pressure side: app. 0.9 -1.0 bar
Troubleshooting
Certain simple repairs of the air conditioner can be performed by untrained personnel. The
coolant circuit hoses and connections must never be loosened. If there are any doubts,
please contact an authorised company for advice. It is not permitted to discharge coolant into
the air.
Also keep in mind that the hoses and pipelines on the pressure side hold a 10 bar pressure,
therefore, be careful when working close to it.
Unsufficient cooling or none at all
Check that
• the v-belt is unbroken and tight

• the fuses and the electric connections to the various consumers are intact.
• the heater fan and condenser blower are working
• the ventilator inlet filter is clean
• the condenser unit is clean and the air can freely pass through.
• the system must be correctly filled (check the gauge of the liquid tank (dry filter)).
Bubbles in the gauge may occur, but only while the condenser switches on or off. In
case of bubbles, the system must be refilled by trained personnel. The system must
not be used before the defect has been repaired, otherwise you risk a compressor
breakdown.
Most systems are fitted with a pressure sensor cutting off the power supply to the compressor
in case of too low or too high pressure.
Too low pressure may occur in case of a coolant leakage or if the surrounding temperature is
too cold.
Too high pressure may occur in case of moisture in the system, a clogged condenser or
defective condenser blower.
In these cases, the compressor does not start and there is no cooling at all.
The system does not cool, the air from the ventilation atomizers is not cooled down.
• The magnetic coupling on the compressor does not engage. Replace compressor.
• The cable connections are loose. Reconnect disconnected cables.
• Fuse F13 or F14 is burned out. Change fuse.
• The compressor does not pump any coolant. The expansion valve is frozen. Change
the tank (dry filter). Drain the system and refill it.
The compressor turns off shortly after the cooling system has been filled.
• The cooling system is not filled correctly. Check the filler pressure. Check the gauge.
Loss of coolant in the system
• The cooling pipe/hoses are defective and must be replaced.

• The compressor is leaking oil. Check the gauge. Change the compressor.
The cooling system emits cooled air for a short while and then warm air again.
• Development of ice in the expansion valve. Change the tank (dry filter). Drain system
and refill.
The system turns off automatically.
• Very high outdoor temperature, see page 7.
Fresh air from the ventilation nozzles is dispersed in the cab, but not enough to
cool the cab
• The vaporizer is dirty and must be cleaned.

• The vaporizer is defective and must be replaced. Drain the system and refill.
• The coolant level is too low. Check the gauge. If necessary, fill up with coolant.
• Doors and windows must be closed.
The fan does not reach its highest performance.
• The cables are not correctly connected. Check connections.
The compressor is too noisy
• The compressor oil level is too low – outer leakage is a visible sign. Change
compressor. Drain system and refill.
Moisture in cab, water drips through the ventilation nozzles
• Drain hoses are clogged or fitted incorrectly. Check hoses, and if necessary, blow
compressed air through the hoses.
The state of the coolant liquid
Beside the liquid tank (dry filter), there is a moisture indicator that shows the degree of
saturation. This indicator changes colour when the moisture is too high.
Colour: Blue = Dry (OK)
Colour: Pink = Moist (the liquid tank has to be replaced)
Gauge
Clear (correctly filled).

When the gauge is clear, it indicates that the system
is filled with the correct amount of coolant.
However, it may also mean that the system is
completely drained of coolant.
Bubbles (not enough coolant in the system).

Foam or bubbles in the gauge indicate that the
system is leaking coolant, and/or air has entered
the system. Bubbles can also appear when
the compressor stands still or when you switch
the system on, but they should disappear after a
short while.
Lines of oil (circulation of compressor oil).

If lines of oil appear in the gauge, the circuit
may lack coolant or there is too much oil.
Dark gauge (moisture-absorbing material circulating).

A dark gauge indicates that the moisture-absorbing
material in the system has decomposed and is
circulating in the system.
Scattered bubbles (not enough coolant or filled (”saturated”) filter)

If there are any scattered bubbles in the gauge, the
coolant level in the system may be lower than it should
be. Another reason could be that the filter is saturated
with moisture and therefore emit bubbles with moisture into
the system.
USER’S MANUAL
On warm summer days with normal atmospheric humidity
1. Close recirculation shutters, if there are any.

2. Turn off the heat.
3. Start the air conditioner.
4. Adjust the temperature to the cooling level you want.
On very warm summer days with high atmospheric humidity
1. Open recirculation shutters, if there are any.

2. Turn off the heat.
3. Start the air conditioner
4. Adjust the temperature to the cooling level you want.
On spring and autumn days with high atmospheric humidity, and when the windows
are steamy.
1. Start the air conditioner

2. Open the recirculation shutters, if there are any.
3. Turn on the wanted heat.
4. Increase or reduce the fan speed until the windows are clear and the cab air is
balanced.
Checkpoints to be controlled once a week if the system is in continuous use

• Check the gauge. Bubbles may only appear while the compressor is turning on/off.
• Check that the coupling between the compressor pressure plate and v-belt is clean
and runs steadily.
• Check the v-belt and tightening points of the compressor.
• Check that there is free passage through the condenser unit and that it is clean.
• Check and, if necessary, clean or change filter elements for fresh air and
recirculation air.
• Check that the drain hoses from the cooling unit are clean and not clogged.
• Check the condition of cooling hoses and make sure that the hoses do not touch
any moving parts.
Circuit diagram for air conditioner GR2 KL.15
A/C ON/OFF S44
For fan switch
Temperature sensor
12V relay 30A
Pressure sensor/low
pressure
Pressure sensor/high
Magnetic coupling (compressor)
pressure
KL31 (frame)

Hydrema 912C Rep - Man GB

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REPAIR MANUAL

Tightening torque for screws

* for countersunk Allen screws quality 10.9, use this section.

Tightening torque for brackets

Manufacturer Type Pipe dimension Screw size Tightening torque N/m

* Stauff “standard” is fitted with a washer.

Fitting of pipes with ring fitting:

Apply hydraulic oil.

c) Tightening: Pipe/ring fitting is fitted into the pipe union.

Fitting of pipe union:

As a minimum, sufficient tape should be applied to cover the

Tightening torque for pipe unions with conical thread

Pipe union Tightening torque N/m

Tightening torque for pipe unions/pipe plugs with cylindrical thread

Fitting of pipes with conical fittings (JIC 37°):

Apply hydraulic oil.

Tightening torque for union (JIC 37o)

Type JIC 37° Tightening torque N/m

Gluing with Loctite

Apply Rocol Heavy Duty Cleaner Spray 00225.

Rinse in clean water and blow-dry with compressed air.

Rinse in clean water and blow-dry with compressed air.

Mount with Loctite 243 (899653) under extremely clean conditions.

Rinse in clean water and blow-dry with compressed air.

Mount with Loctite 270 (899654) under extremely clean conditions.

Rinse in clean water and blow-dry with compressed air.

Mount with Loctite 542 (899702) under extremely clean conditions.

Drying time: Min. ½ hour before immersion in oil.

Axle/hub joints on the vehicle are all

1. Removal with impact puller

Equipment: impact puller

a) remove M12 screw (pos.4) and locking element (pos.3)

2. Removal with puller tools

The instructions apply to removal with manual “puller tools”.

Equipment: puller (090099)

a) remove M12 screw (pos.6) and locking element (pos.5)

1. Removal with hydraulic puller tools

Equipment: hydraulic puller tools (090055)

Description of fault codes:

First number Meaning of the number

o.c. open curcuit

Definitions of operating modes:

Substitute clutch control:

1.3 Display in work

Symbol Meaning Remarks

WR Warning signal – retarder temperature Shift between selected gear /

WE Warning signal – high number of revolutions. Shift between selected gear /

selected direction of travel while

PN Driving direction F or R is chosen while parking brake Transmission in neutral until

The display while in AEB mode

Symbol Explanation Notes

Resistance: 1050 Ohm (+/- 10%) at 200C

Temperature range: -400C ---> + 1500C

Torque limit: 30Nm

Data for Hall-Sensor of the Output.

Temperature range: -400C ---> + 1500C

Working range: 2Hz ---> 5 Khz

Data for Proportional valves.

Resistance: 19Ohm (+/- 10%) at 200C

Current: 100 ---> 500mA

Pressure range: 0,8 bar ---> 8,3 bar

Data for temperature sensors.