4 6 Suspension – 6.

2 Suspension

6.2 Suspension
Suspension, description
page
–

The steering axle cradle is attached to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on rotating king pins. The king pins turn to steer the machine.
The wheel spindles have bearings for the wheel hubs, to which the
wheels are attached.

Suspension, position of the components

–

Suspension refers to:

4
• Steering axle cradle

5 • Wheel spindle
1
2 • Wheel hub
3
007811

11 10 9 8 7 6
1. Steering axle cradle
2. Fixing lug
3. Rubber damper
4. Tyre
5. Rim
6. Steering cylinder
7. Piston rod
8. Link arm
9. Wheel spindle
10. Hub
11. Bolts

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

 6 Suspension – 6.2.1 Steering axle cradle 5

6.2.1 Steering axle cradle

Steering axle cradle, description
page
–

The steering axle is pendulum suspended with a double-acting steer-

ing cylinder. The construction comprises a minimum of moving parts
to minimise service points and simplify maintenance.
The chassis suspension comprises maintenance free parts. The rear
suspension is designed with a fixed bolted joint.

Steering axle cradle, replacement

page
–

DANGER
Steering axle and machine are very heavy.

Risk of crushing!

It is not permissible to go under a machine which has

been lifted by a jack or similar. For machine weights,
please refer to section F Technical data.

1 Machine in service position, see section B Safety.

2 Place supports under the counterweight under the machine.
3 Remove the steering wheels.

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

6 6 Suspension – 6.2.1 Steering axle cradle

4 Raise the steering axle cradle slightly.

5 Release the cables from the steering angle sensor (only refers to
machines with lever steering).
6 Place a receptacle under the hoses on the steering cylinder.
7 Mark up and detach the hydraulic hoses from the steering cylin-
der.

NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.

8 Remove the circlip from the stub axle in the front and rear attach-
ment points.
9 Knock out the stub axle with a sledge hammer.
10 Move aside the steering axle cradle in a suitable way.

CAUTION
The steering axle may start to roll.

Crushing injury!

Make sure that the steering axle does not start uncon-
trolled movement.

11 Lift the new steering axle into place under the frame.
12 Install axle in the front and rear attachment points. Install circlips
on the stub axles.

NOTE
Lubricate attachment point and axle with copper paste or equiv-
alent to prevent corrosion.
13 Connect the hydraulic hoses to the steering cylinder in accord-
ance with the marking.

NOTE
Check that the O-rings are intact and that they are fitted cor-
rectly.
14 Connect the cables to the steering angle sensor (only refers to
machines with lever steering).
15 Remove the lifting equipment from the machine.

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

 6 Suspension – 6.2.2 Wheel spindle 7

6.2.2 Wheel spindle

Wheel spindle, description
page
–

The wheel spindle is the link between steering axle and wheel hubs
which allows the wheels to be turned.
The wheel spindle is provided with a roller bearing (lower bearing) and
a tapered roller bearing (upper bearing).

3
2

4
5
1 6
8 7

9
009780

11 10
1. Wheel spindle
2. Seal ring
3. Tapered roller bearing (upper bearing)
4. Protection ring
5. Seal ring
6. Roller bearing (lower bearing)
7. Retaining ring
8. Shims
9. Bearing holder
10. Allen screw
11. Grease nipple

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

8 6 Suspension – 6.2.2 Wheel spindle

Wheel spindle and wheel spindle bearings,

page
–

replacement
1 Machine in service position, see section B Safety.
2 Remove the wheel (steering).

DANGER
Tyres should be regarded as pressurized containers.
They constitute fatal danger if handled incorrectly.

Parts can be thrown with explosive force and may

cause severe injuries.

Never repair damaged tyres, rims or lock rings. Tyre

repairs should only be performed by authorized per-
sonnel.

3 Clean the wheel spindle and its surrounding area.

4 Detach the link arm from the wheel spindle, see section 5 Steer-
ing, group 5.2.6 Link arm.
5 Remove the wheel hub and wheel bearing, see Wheel hub and
wheel bearings, replacement page 11.
6 Remove the six Allen screws securing the bearing holder to the
wheel spindle.

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

 6 Suspension – 6.2.2 Wheel spindle 9

7 Remove the bearing holder by screwing a bolt into the removal

hole.
8 Release the bearing holder and shims from the wheel spindle.
9 Remove the wheel spindle.
10 Unscrew the three screws above the steering spindle´s upper
bearing, on top of the steering cradle. Depress the upper bearing
outer race by screwing three screws (lenght approximately 90
mm) into the holes.
11 Remove the inner race of the upper and lower bearing from the
steering wheel spindle.
12 Pull the lower bearing outer race from the bearing holder.

002419
13 Tap the outer race of the upper bearing into the steering wheel
cradle from below, using a piece of tube.
14 Fit the three screws back into their holes.
15 Attach upper bearing´s inner race and seal ring, protection ring,
seal ring, lower bearing inner race and retaining ring to the wheel
spindle.
16 Fit the wheel spindle.
17 Tap the outer race of the lower bearing into the bearing holder.
18 Position the bearing holder and tighten it with shims, tighten the
six screws to 70 Nm.
19 Check that the wheel spindle rotates smothly with at maximum
play of 0.25 mm. If not, adjust with shims.
20 Lubricate the bearings by means of the grease nipples.
21 Fit the wheel hub and wheel bearing, see Wheel hub and wheel
bearings, replacement page 11.
22 Fit the link arm to the wheel spindle, see section 5 Steering,
group 5.2.6 Link arm.
23 Mount the wheel.

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

10 6 Suspension – 6.2.3 Wheel hub

6.2.3 Wheel hub

Wheel hub, description
page
–

The wheel hub holds the wheel in place and enables the wheel to ro-
3 2
tate. The hub is provided with two tapered roller bearings.
1
4
5
6

7
8
9
10 11
008595

1. Hub
2. Wheel bolt
3. Wheel nut
4. Hub cap
5. Spacer
6. Nut
7. Washer
8. Bearing
9. Screw
10. Bearing
11. Dust shield

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

 6 Suspension – 6.2.3 Wheel hub 11

Wheel hub and wheel bearings, replacement

page
–

1 Machine in service position, see section B Safety.

2 Remove the wheel (steering).

DANGER
Tyres should be regarded as pressurized containers.
They constitute fatal danger if handled incorrectly.

Parts can be thrown with explosive force and may

cause severe injuries.

Never repair damaged tyres, rims or lock rings. Tyre

repairs should only be performed by authorized per-
sonnel.

3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Remove excess grease with a rag. Treat as environmentally haz-
ardous waste

6 Open the lock washer with a screw driver.

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

12 6 Suspension – 6.2.3 Wheel hub

7 Remove the lock nut, lock washer and the bearing nut.

8 Remove the spacer washer from the bearing.

9 Remove the entire hub including the outer bearing.

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

 6 Suspension – 6.2.3 Wheel hub 13

10 Remove the inner bearing inner race from the wheel spindle.
11 Remove the bearings' outer races from the hub.
Use a drift and press out the bearing races.
12 Remove the seal.
13 Clean the hub and smear the inside with universal grease “EP2”.
14 Fit new sealings and bearing races in the hub.
Use a drift and press in the bearing races. Never use directly on
the bearings.

NOTE
Fit the outer bearings with the larger diameter outward.
15 Fit the inner bearing inner race and rollers on the wheel spindle.
Pack in the bearing with universal grease “EP2”.

16 Fill the empty space in the hub with universal grease “EP2”.

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

14 6 Suspension – 6.2.3 Wheel hub

17 Fit the hub on the wheel spindle.

18 Fit the outer bearing and spacer washer and bearing nut.
Pack in the bearing with grease and fit the bearing.
Fit the washer and bearing nut with the smooth surface in to-
wards the hub.

19 Torque the bearing nut as follows.

A. Grease the thread on the side of the nut turned to the bearing
with oil (SAE 80W140).
B. Tighten the nut during rotation of the hub.
C. Rotate the hub at least 10 revolutions.
D. Retighten the nut during rotation of the hub.
E. Repeat procedure B-D until the nut does not move when
009177

retightened.
F. Check friction torque as below:
The lower limit with no play will be reached when tightening
the bearing nut until no play could be felt when trying to wob-
ble the wheel.
The upper limit could be checked with a spring balance which
gives the maximum friction torque, the friction torque should
be approximately 14.5 Nm.

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

 6 Suspension – 6.2.3 Wheel hub 15

Max 8 kg

360 mm

009168
Wind a cord a few times around the wheelbolts before the wheel is
mounted and pull with the spring balance. Read the scale when hub is
rotated.
20 Grease the lock washer and fit it.
21 Fit the lock nut and tighten with a minimum torque of 250 Nm or
as hard as necessary to be able to turn the lock washer in the
nearest groove. Lock the bearing nut and lock nut with the lock
washer.

22 Fill the bearing casing with grease and fit it.

23 Grease the wheel bearing with grease through the grease nipple.
Rotate now and then to distribute graese inside wheel hub, lift the
seal ring's lip with a small screwdriver to enable air to escape.
Grease until grease comes out by the seal.
24 Fit the wheel.
25 Remove the support and lower the steering wheel.
007862

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

16 6 Suspension – 6.3 Tyres and rims

6.3 Tyres and rims

Tyres and rims, safety
page
–

DANGER
Always block the wheels on the side of the axle where
no work is to be done before positioning the jack. Al-
ways secure the jack to prevent it from sliding out of
position.

Fully deflate the tyre before removal. Otherwise parts

from the wheel rim can loosen and shoot out when the
pressure is changed. With double wheel fitting both
tyres must be fully deflated!

The air should always be released through the valve.

If this is not possible - drill holes in the tread to re-
lease the air. Damaged tyres may explode.

Never stand directly opposite the tyre when deflating

or inflating. Parts from the wheel rim may release and
shoot off when the pressure changes.
001639

Never install damaged tyres or rims.

It’s prohibited to repair rims with welding.

It’s prohibited to operate the machine if one of the

tyres is flat.

Wheels, tyres, and rims are dimensioned and select-

ed for each machine type so that maximum wheel
loads and speeds are not exceeded. For this reason,
it is not permitted to change tyre dimension, tyre
make, tyre type, rim type, or rim brand without ap-
proval from Cargotec.

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

 6 Suspension – 6.3 Tyres and rims 17

CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.

When removing drive wheels, make sure that the

wheels are fixed when the spacer rings are removed.
If the wheels move, they may move the spacer rings
and crushing damage may result.

When installing drive wheels, ensure that the clamps

clamp straight on the spacer ring.

Wheel nuts should be check-tightened after

4–5 operating hours.

Always follow the tyre manufacturer’s or other ap-

proved instructions when changing tyres.

Never use a steel hammer to install or remove rim

components. Instead, use a lead, brass or plastic
mallet.

Keep the tyre pressure at the prescribed level. Insuf-

ficient tyre pressure impairs stability and reduces the
machine’s capacity.

Remove penetrating objects such as crushed glass,

pieces of wood, metal filings, etc.

Check if tyre wear is abnormal, this could indicate a

mechanical fault. Rectify faults immediately and
change damaged tyres.

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

18 6 Suspension – 6.3.1 Tyres

6.3.1 Tyres
Tyres, description
page
–

The tyres are the machine's contact with the ground, the tyres absorb
rough surfaces and act as suspension.
The drive axle is exposed to great stresses during operation, and the
stresses increase if the drive wheels' rolling circumference differs. It is
important that the tyres on the drive axle are of the same model, type
and make, and have similar wear and the correct air pressure.
Spare and exchange tyres shall be of a make approved by Cargotec.

001865

Rear wheels
002673

Front wheels

Tyres, replacement
page
–

DANGER
Changing tyres is complicated and dangerous work.

EXTREME DANGER!

Leave tyre work to authorised personnel/tyre compa-

ny.

The rims must be checked when tyres are changed. See Maintenance
manual.

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

 6 Suspension – 6.3.2 Rims 19

6.3.2 Rims
Rim, description
page
–

The rim is split to make it possible to fit a tyre. The rim consists of the
following parts.
• Rim
• Lock ring
• Side ring
• Tapered ring

3 2

1
007777

1. Lock ring
2. Side ring
3. Tapered ring

6.3.3 Nut, washer and clamp (wedge)

Nut, washer and clamp, description
page
–

The rim is secured to the wheel hub with nuts (washer integrated in the
nut).
Clamps are not used here.
10 nuts are always used on this machine and these can be used as
follows:
• Drive axle with hub reduction, nuts with integrated washers.
• Steering axle, nuts with integrated washers.
• Steering axle with nut caps (protection).

NOTE
Two different type of nuts when protection plate is mounted.

Bolt equipment, replacement

page
–

1 Machine in service position, see section B Safety.

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

20 6 Suspension – 6.3.3 Nut, washer and clamp (wedge)

2 Lift the machine under the counter weight.

3 Remove the wheel.

4 Knock out the bolt with a sledge hammer.

5 Install the new bolt.

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

 7 Load handling 1

7 Load handling

Table of Contents 7 Load handling

mm mm mm mm mm mm

7 Load handling................................................................................................. 3
7.1 Controls and instruments ........................................................................... 3
7.1.1 Control lever .......................................................................................... 3
7.2 Lifting/lowering ........................................................................................... 8
7.2.1 Hydraulic oil pump ............................................................................... 12
7.2.2 Accumulator ......................................................................................... 12
7.2.3 Main valve ............................................................................................ 12
7.2.4 Lift cylinder ........................................................................................... 13
7.2.5 Accumulator damping .......................................................................... 13
7.2.6 Mast ..................................................................................................... 14
7.2.7 Mast wheels ......................................................................................... 22
7.2.8 Chains .................................................................................................. 30
7.2.9 Chain wheels and hose wheels ........................................................... 31
7.2.10 Fork carriage ........................................................................................ 34
7.2.11 Load control valve ................................................................................ 38
7.2.12 Pipes and hoses .................................................................................. 39
7.4 Side shift ................................................................................................... 40
7.4.1 Hydraulic oil pump ............................................................................... 43
7.4.2 Accumulator ......................................................................................... 43
7.4.3 Main valve ............................................................................................ 43
7.4.4 Side shift cylinder ................................................................................. 44
7.4.5 Side shift frame .................................................................................... 46
7.4.6 Fork carriage ........................................................................................ 46
7.4.7 Pipes and hoses .................................................................................. 46
7.5 Spreading ................................................................................................. 47
7.5.1 Hydraulic oil pump ............................................................................... 50
7.5.2 Accumulator ......................................................................................... 50
7.5.3 Main valve ............................................................................................ 51
7.5.4 Flow divider .......................................................................................... 52
7.5.5 Spreading cylinder ............................................................................... 53
7.5.6 Fork carriage ........................................................................................ 53
7.5.7 Pipes and hoses .................................................................................. 53
7.7 Tilt ............................................................................................................. 54
7.7.1 Hydraulic oil pump ............................................................................... 58
7.7.2 Accumulator ......................................................................................... 58
7.7.3 Main valve ............................................................................................ 58
7.7.4 Load holding valve (over-centre valve) ................................................ 59
7.7.5 Tilt cylinder ........................................................................................... 60
7.7.6 Mast ..................................................................................................... 62
7.7.7 Pipes and hoses .................................................................................. 62
7.8 Levelling ................................................................................................... 63
7.8.1 Hydraulic oil pump ............................................................................... 66
7.8.2 Accumulator ......................................................................................... 66
7.8.3 Main valve ............................................................................................ 67

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

2 7 Load handling

7.8.4 Levelling cylinder .................................................................................. 68

7.8.5 Fork carriage ........................................................................................ 69
7.8.6 Levelling fork ........................................................................................ 69
7.8.7 Pipes and hoses ................................................................................... 69
7.9 Load carrier ............................................................................................... 70
7.9.1 Lift forks ................................................................................................ 70
7.10 Other functions .......................................................................................... 72
7.10.1 Electric scales ...................................................................................... 72
7.10.2 Pre-selected lift height .......................................................................... 74
7.10.3 Vertical alignment ................................................................................. 75
7.10.4 Optimum lift ......................................................................................... 76
7.10.5 Side lift attachment ............................................................................... 76

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

 7 Load handling – 7 Load handling 3

7 Load handling
mm mm mm mm mm mm

7.1 Controls and instruments

7.1.1 Control lever
Control lever, replacement
page
–

1 Machine in service position, see section B Safety.

2 Depressurize the hydraulic system, see section B Safety.
3 Remove the cover from the control levers (six screws).

4 Detach the control levers from the bracket (four screws).

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

4 7 Load handling – 7.1.1 Control lever

5 Cut the cable tie and fold down the gaiter to expose the control
levers' connections.
6 Lift the control levers off the bracket.

7 Remove the hose connections.

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

 7 Load handling – 7.1.1 Control lever 5

8 Unscrew the control levers.

9 Replace the control lever in question. Replace also the O-ring in
case of leakage.
10 Check that there are no leaks when the levers are refitted.
11 Fit in the reverse order.

Electric hydraulic servo, description

page
–

The electrical servo makes possible the use of small fingertip control-
led linear levers, or a “joystick”, for the different functions of the work-
ing hydraulics.
The control levers contain potentiometers. The output signals from
these are handled in ECU 796 and then used for control of electro-hy-
draulic proportional valves (see Workshop Manual, section 10 Com-
mon hydraulics, group 10.5.5 Proportional valves). These convert the
output signals from ECU 796 to hydraulic servo pressure which then
controls the control slides in the hydraulic system main valves.
During operation, the output signals are changed via two break points
in proportion to the lever deflections, which gives direct control of the
main valves. An IIR-type of filter and a ramp for lift/lower have been
added to damp high frequency interference from the surroundings and
to obtain smooth hydraulic movements but with maintained speed.
The lower movement has a longer ramp time than lift.
There is an operating switch beside the electric servo levers/joystick.
When pressed, it cuts off voltage supply to the PWM outputs in
ECU796. Then, no hydraulic functions can move. Red light-emitting di-
ode on the end of ECU796 flashes if emergency stop is pressed.
Green light-emitting diode is activated with a fixed glow if the supply
voltage is between 22 – 28V, flashes with high frequency if voltage is
above 28V and with lower frequency if voltage is below 22V. Yellow
light-emitting diode is activated with a fixed glow if communication on
the CAN-bus is correct. The output signal is broken in two points for
better fine feel. Break point 1 (BP1) is pre-set so that at 40% of the le-
ver movement, the ECU gives 20% of max. output signal. Break point
2 (BP2) is set so that at 80% of the lever movement, the ECU gives
60% of max. output signal. Thus, at 100% lever movement, the ECU
gives 100% output signal.

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

6 7 Load handling – 7.1.1 Control lever

The control of the main valve (diagram y-axis) is not proportional to the
out lever angle (diagram x-axis). This gives a better response with small
lever angles.
The following signals are monitored:
• control levers or joystick
in

001632
• proportional valves (impedance and current)

Function test
–

In general, test all hydraulic functions to make sure that they react and
move in the correct direction. The speed of the movements may need
to be adjusted individually for each machine, for example, side shift
may be too fast at times, then max. current shall be set to a lower value
for respective solenoid valve.
1. Dead zone. Check if the dead zone is sufficient by test-running the
machine on a rough surface and note if any hydraulic function
moves. If it does, increase the dead range, for example, 10 steps.
2. Lift/lower movement. Check smoothness of movement at idle and
max. rpm.
3. Tilt in/out. Same as lift/lower.
4. Side shift. Same as lift/lower.
5. Positioning (spreading). Same as lift/lower.
6. Levelling. Same as lift/lower.

Trouble shooting
–

For error code tables, see section D Error codes.

A number of fault tracing examples are shown below.

Symptom. Lift/lower does not function!

• Error code 610. No or incorrect signal from lift/lower lever. If signal
is outside calibrated values for more than 100 ms, the alarm is
generated. Try re-calibrating the lever. If this doesn’t work, re-
place the lever.
• Error code 615 or 616. Short-circuit or open circuit in solenoid
valve for lift/lower. Check if connector to valve block is pushed in
enough. Alternatively, measure resistance in spool for solenoid
valve. It should be approx. 20 Ohm, not below 15 Ohm.

Symptom. Tilt in/out does not function!

• Error code 611. See lift/lower above.
• Error code 617 or 618. See lift/lower above.

Symptom. Side shift does not function!

• Error code 612. See lift/lower above.
• Error code 619 or 620. See lift/lower above.

Symptom. Positioning (spread) does not function!

• Error code 613. See lift/lower above.
• Error code 621 or 622. See lift/lower above.

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

 7 Load handling – 7.1.1 Control lever 7

Symptom. Levelling or 5th function does not function!

• Error code 614. See lift/lower above.
• Error code 623 or 624. See lift/lower above.

Symptom. No response in any hydraulic function.

• Error code 604. Voltage supply 24V to PWM outputs missing.
Check if operating switch by the electric servo levers is pressed
down. If electric servo still doesn’t function, check fuse 58-4 no. 7
(10A) for DCE90-180. Otherwise, supply internally in ECU is de-
fective and it must be replaced.
• Error code 603. Voltage supply 10V reference to electric servo le-
vers missing. Measure 10V reference from ECU between termi-
nals X46.7 (0V) and X46.6 (10V) for DCE90-180. If there’s no 10V
or voltage is below 9V or above 11V, then supply from ECU is de-
fective and it must be replaced.
• Error code 601. Voltage supply to ECU 796 below 14V or above
33V or missing. Check fuse 58-4 no. 7 (5A) for DCE90-180.
• Error code 602, 605 or 606. Hardware error on ECU796. Try to re-
start the system with the ignition key. If this doesn’t work, the ECU
has to be replaced.

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

8 7 Load handling – 7.2 Lifting/lowering

7.2 Lifting/lowering
Lifting/lowering, function description (hydraulic
page
–

servo)

9
6 8
11
10

C
4
3, 5, 7
PP
PA

B
ACK2
TA

b
9
8
P2
T1
C
P

A
T

a
11
10

2 2 2 C

1 1 1

014834

Pos Explanation Signal description Reference

1 The hydraulic oil pumps pumps oil from See pressure plate on Section 10 Common hydraulics, group
the hydraulic oil tank. left-hand front mudguard. 10.4.1 Gear pump with fixed displacement

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group

10.6.8 High-pressure filter/Return filter

3 The accumulator charging valve in the - Section 10 Common hydraulics, group

valve block directs oil to charging of the 10.5.2 Control valve
accumulator.

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group
left-hand front mudguard. 10.3.2 Accumulator

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

 7 Load handling – 7.2 Lifting/lowering 9

Pos Explanation Signal description Reference

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group
duces the pressure from hydraulic oil 10.5.2 Control valve
pump 3 to servo pressure.

6 Control lever, lift and lower, controls ser- -

vo pressure in proportion to lever move-
ment to control valve load
handling.

7 The servo pressure from control lever, - Main valve, description (hydraulic servo)
lift and lower, acts on the lift slide in con- page 12
trol valve, load handling, which changes
position and pressurizes the lift cylin-
ders.

8 Lifting or lowering the fork carriage - Load control valve, description page 38
(free lift)
During lifting, the load control valve
opens and directs pressure on to the lift
cylinders. The free lift cylinders start to
move at a lower pressure, since their
area is 15-20% greater than in the lifting
cylinders.
During lowering, the load control valve is
closed and directs limited flow from the
free lift cylinder.

9 The free lift cylinder raises or lowers the - Lift cylinder, description page 13
fork carriage in relation to the inner
mast.

10 Lift or lower mast - Load control valve, description page 38

The load control valve opens and directs
pressure on to the lift cylinders.

11 The lift cylinders raises or lowers the in- - Lift cylinder, description page 13
ner mast in relation to the outer mast. Lift masts, description page 14

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

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

10 7 Load handling – 7.2 Lifting/lowering

Lifting/lowering, function description (electrical

page
–

servo)

Condition Reference value Reference

Control switch Disengaged Section 11 Common electrics, group 11.5.1.4
Emergency stop voltage (15E)

7 ECU796 11
D7 10
6 13
D6
12
4
8
3, 5, 9
PA

B
ACK2
TA

11
10
P2
T1

C
P

A
T

13
8 12

2 2 2 C

1 1 1

014833

Pos Explanation Signal description Reference

1 The hydraulic oil pumps pumps oil from See pressure plate on Section 10 Common hydraulics, group
the hydraulic oil tank. left-hand front mudguard. 10.4.1 Gear pump with fixed displacement

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group

10.6.8 High-pressure filter/Return filter

3 The accumulator charging valve in the - Section 10 Common hydraulics, group

valve block directs oil to charging of the 10.5.2 Control valve
accumulator.

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group
left-hand front mudguard. 10.3.2 Accumulator

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

 7 Load handling – 7.2 Lifting/lowering 11

Pos Explanation Signal description Reference

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group
duces the pressure from hydraulic oil 10.5.2 Control valve
pump 3 to servo pressure.

6 The control lever, lifting and lowering U = 0-10 V DC D6: Diagnostic menu, see section 8 Control
(R8071), sends a voltage signal which is system, group 8.4.4.1 View inputs, menu 3,
proportional to the lever movement to ECU 796 input K1:9
the Control Unit hydraulics (ECU 796).

7 The Control Unit Hydraulics (ECU 796), - Main valve, description (electrical servo)
sends a current signal to the solenoid page 12
valve for mast lifting (Y6005) or the sole- D7: Diagnostic menu, see section 8 Control
noid valve for mast lowering (Y6004). system, group 8.4.4.2 View outputs, menu
1, ECU 796 output K2:3 (lower), output K2:4
(lift)

8 Solenoid valve, mast lifting (Y6005) or - Main valve, description (electrical servo)
the solenoid valve for mast lowering page 12
(Y6004) allocates servo pressure in pro-
portion to the control current in the lifting
slide in control valve load handling.

9 The control valve lifting slide changes - Main valve, description (electrical servo)
position and pressurizes the lift cylin- page 12
ders.

10 Lifting or lowering the fork carriage - Load control valve, description page 38
(free lift)
During lifting, the load control valve
opens and directs pressure on to the lift
cylinders. The free lift cylinders start to
move at a lower pressure, since their
area is 15-20% greater than in the lifting
cylinders.
During lowering the load control valve is
closed and directs limited flow from the
free lift cylinder.

11 The free lift cylinder raises or lowers the - Lift cylinder, description page 13
fork carriage in relation to the inner
mast.

12 Lift or lower mast - Load control valve, description page 38

The load control valve opens and directs
pressure on to the lift cylinders.

13 The lift cylinders raises or lowers the in- - Lift cylinder, description page 13
ner mast in relation to the outer mast. Lift masts, description page 14

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

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

12 7 Load handling – 7.2.1 Hydraulic oil pump

7.2.1 Hydraulic oil pump

Hydraulic oil pump, description
page
–

Please refer to section 10 Common hydraulics, group 10.4.1 Gear

pump with fixed displacement.

7.2.2 Accumulator
Accumulator, description
page
–

See section 10 Common hydraulics, group 10.3.2 Accumulator.

7.2.3 Main valve

Main valve, description (hydraulic servo)
page
–

Lifting/lowering is controlled by a separate section of the main valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information on lifting/lowering, see Lifting/lowering, function
description (hydraulic servo) page 8.

Lift slide
When the lift control lever is activated, pressure is applied to the lift
spool, which controls the direction and flow of oil from the hydraulic oil
pump to the lift cylinders. See Lift cylinder, description page 13.

Main valve, description (electrical servo)

page
–

Lifting/lowering is controlled by a separate section of the main valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information on lifting/lowering, see Lifting/lowering, function
description (electrical servo) page 10.

Lift slide
The lift slide controls direction and flow of oil to the lift cylinder.

Servo valve, lift mast

The servo valve for lifting is controlled electrically by Solenoid valve lift
(Y6005), which is activated by Control unit hydraulics (ECU 796). The
servo valve actuates the servo pressure to the lift spool. This pressure
is proportional to the control current to the solenoid valve.

Servo valve, lower mast

The servo valve for lowering is controlled electrically by Solenoid valve
lower (Y6004), which is activated by Control unit hydraulics (ECU
796). The servo valve actuates the servo pressure to the lift spool. This
pressure is proportional to the control current to the solenoid valve.

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

 7 Load handling – 7.2.4 Lift cylinder 13

7.2.4 Lift cylinder

Lift cylinder, description
page
–

The lifting cylinders lift and lower the inner mast, which runs inside the
outer mast. The lower parts of the lifting cylinders are fixed to the outer
mast, whereas their upper parts are fixed to the inner mast, one on the
right and one on the left of the mast.
The lift cylinders are connected in parallel and fed from control valve
load handling, see Load control valve, description page 38.
The cylinder head is threaded in the cylinder barrel (and can be re-
moved using a hook wrench if needed). When the cylinder is recondi-
tioned and the cylinder head is to be remounted, it is very important
that the piston rod is unloaded exactly so that the threads aren't dam-
aged.
There are double piston rod seals on the cylinders (applies to all cylin-
ders for load handling). The bearing arrangement consists of guide
bushings that hold the piston rod in the center of the cylinder.
For images of the lift cylinders, see Lift masts, description page 14.
The lift cylinders for the mast duplex free-lift are provided with end-po-
sition damping. This function means that when the cylinders approach
their bottom position, the oil flow out from the cylinders is restricted.
The oil flow is forced through a gap between the piston end and the
cylinder bottom. To ensure the cylinders' lift movement from the bot-
tom position, a non-return valve directs oil past the restriction.

Hydraulic cylinders, repairing

page
–

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

7.2.5 Accumulator damping

Accumulator damping, description
page
–

This accumulator, which is only intended for the lift and lower function,
is of the piston accumulator type (not to be confused with the dia-
phragm accumulator in group 10 Common Hydraulics). It is an option
that significantly improves damping performance when lifting and low-
ering loads.
The piston accumulator is connected to the lift cylinders and provides
a damping function in the cylinder, e.g. when driving on an uneven sur-
face, which can create pressure spikes in the hydraulic system.
The function is ideal for handling rolls of paper, where the friction be-
tween the clamp and the roll of paper is at risk if accumulator damping
is not used. Accumulator damping makes the grip on the roll of paper
is more secure.

NOTE
008410

Handling the accumulator requires special equipment and train-

Piston accumulator ing.

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

14 7 Load handling – 7.2.6 Mast

Accumulator damping, replacement

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety
2 Depressurize the hydraulic system, see section B Safety.
3 Mark up and detach the hydraulic hoses from the accumulator.

1 NOTE
Plug the connections immediately to protect the hydraulic
system from impurities.
4 Remove the accumulator attaching bolts.
5 Remove the accumulator.
6 Charge the new accumulator. As standard, it should be charged
with 10 MPa preload pressure. This pressure can be lowered to
008411

2 3 achieve the desired functionality.

7 Transfer the connection adapters to the new accumulator.
8 Fit the new accumulator.
1. Piston accumulator
2. Nipple 9 Connect the hydraulic hoses to the accumulator in accordance
3. Bolt and mounting clamp (2 pc.) with the marking.

NOTE
Check that the O-rings are intact and fitted correctly.
10 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
11 Test the lifting and lower a couple of times.
12 Check that the accumulator's connections are sealed tightly.

7.2.6 Mast
Lift masts, general
page
–

The lift masts that are available are: duplex standard, duplex freelift
and triplex freelift. The duplex alternatives have an outer as well as an
inner mast, while the triplex freelift also has a middle mast.

Lift masts, description

page
–

The mast lifts the load. The fork carriage runs on the mast, and holds
the forks, attachment or coil ram in its turn.
The lower part of the mast is fixed to the frame by two shafts in the lugs
on the front part of the frame. The mast is also fixed to the frame by
two tilt cylinders.
The lift masts, both duplex as well as triplex, are based on a free-visi-
bility concept. The number of welds has been reduced to a minimum
for maximal strength, and stresses on the mast parts are low. All mast
wheels are provided with high-quality bearings.

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

 7 Load handling – 7.2.6 Mast 15

Side (lateral) control of the inner mast (inner and middle mast on tri-
plex) is achieved using sliding plastic blocks at the upper end of the
outer mast and the lower end of the inner mast.
Duplex standard, description
Oil is forced into the lift cylinders. The lift cylinder piston rod is attached
to the inner mast, which is lifted. The chain that is attached in the car-
riage (and in the outer mast) runs over chain wheels at the top of the
6
inner mast. Thus, the carriage is also lifted at the same time as the in-
5 ner mast.
4
11

3
9

1
10
000903

2
7
Duplex standard
1. Outer mast
2. Inner mast
3. Lift cylinders
4. Chain tensioner
5. Chain wheel
6. Hose wheel
7. Attachment to frame
8. Nipple
9. Hoses
10. Load control valves
11. Lifting eyes

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

16 7 Load handling – 7.2.6 Mast

Duplex freelift, description

Oil is forced into the lift cylinders. The lift cylinders have a hollow piston
rod that is connected to the freelift cylinders. Through area control
9 (freelift cylinders require lower oil pressure than the lift cylinders to be
10 lifted), the freelift cylinder piston rod is forced out before the lift cylin-
3 ders. At the end of the piston rod on the freelift cylinders, is a wheel
over which a chain runs. The chain is attached to the carriage and the
inner mast, which means that the carriage is lifted at the same time as
5 the freelift cylinders' piston rod is extended.
8 When the freelift cylinders have reached their end position, the pres-
1
sure in the lift cylinders increases and their piston rod lifts the inner
4 mast.

7 The lift cylinders for the duplex freelift mast have end position damping
in the masts lower position, see Lift cylinder, description page 13.

9 Triplex freelift, description

Oil is forced into the lift cylinders. Through area control (freelift cylin-
ders require lower oil pressure than the lift cylinders to be lifted), the
2
freelift cylinder piston rod is forced out before the lift cylinders. At the
001221

6 end of the piston rod on the freelift cylinders is a wheel over which a
Duplex freelift chain runs. The chain is attached to the carriage and the inner mast,
1. Outer mast which means that the carriage is lifted at the same time as the freelift
2. Inner mast cylinders' piston rod is extended.
3. Lift cylinders When the freelift cylinders have reached their end position, the pres-
4. Freelift cylinders sure in the lift cylinders increases and their piston rod lifts the middle
5. Chain wheel mast.
6. Attachment to frame
The chain attached to the inner mast and outer mast runs over a chain
7. Nipple
wheel at the top of the middle mast, which means that the inner mast
8. Hoses
is raised at the same time as the middle mast.
9. Load control valves
10. Lifting eyes The lift cylinders for the triplex freelift mast have end position damping
in the masts lower position, see Lift cylinder, description page 13.

Mast, removing
page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Remove the fork carriage, please refer to Fork carriage, removing
page 35.
2 Machine in service position, see section B Safety
3 Depressurize the hydraulic system, see section B Safety.

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

 7 Load handling – 7.2.6 Mast 17

4 Connect lifting equipment to the lifting lugs on the mast in a se-

cure manner.

008412
5 Undo the mast lighting connector and release the mast lighting
cable.
6 Mark up and undo other electrical connectors if there are any.
008413

7 Put a collection vessel under the mast to collect any spilled oil.
8 Mark and undo the hydraulic connections for the lift cylinders.

NOTE
Plug all connections at once to protect the hydraulic system
from contamination.
008414

9 Secure the tilt cylinder to an overhead crane and release the tilt
1 cylinder from the mast.
Remove the two screws and the lock plate for the shaft.
Remove the cylinder shaft. If necessary, use a slide hammer to
drive the shaft out.
Repeat the procedure for the other cylinder.
2
008415

1. Cylinder shaft
2. Screw and washer

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

18 7 Load handling – 7.2.6 Mast

10 Undo the mast from the machine by undoing the screw and re-
1 moving the shafts which fix the mast to the frame, use two screws
(M24) in the tapped holes puller.

3
WARNING
The mast can swing out when it is released from the
machine.

This can cause personal injury!

008416
1. Shaft
2. Tapped holes (M24)
3. Screw

11 Lift the mast away and lay it on the ground.

12 Undo the lifting equipment (travelling crane).

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

 7 Load handling – 7.2.6 Mast 19

Mast, installing
page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety
2 Depressurize the hydraulic system, see section B Safety.
3 Connect lifting equipment to the lifting lugs on the mast in a se-
cure manner.
4 Lift the mast into place.

008412

5 Install the shafts and fix them with screws.

6 Grease the mast anchorage.
008417

7 Connect the tilt cylinders to the mast.

1
Install the cylinder shaft.

NOTE
Check that the bearing in the cylinder anchorage on the
mast is correctly aligned before the shaft is installed.
2
Rotate the shaft to find correct position for the lock plate.
Mount the lock plate and secure with the two screws.
Repeat the procedure for the other cylinder.
008415

8 Grease the cylinder anchorages.

1. Cylinder shaft
2. Screw and washer

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

20 7 Load handling – 7.2.6 Mast

9 Connect the hydraulic hoses to the lift cylinders in accordance

with the marking.

NOTE
Check that the O-rings are intact and fitted correctly.

008414
10 Fix the mast lighting cable and join the mast lighting connector to-
gether.
008413

11 Undo the lifting equipment (travelling crane).

12 Turn the main switch on and start the engine.
13 Check that the hydraulic connections seal correctly.
14 Extract air from lift cylinders, applies duplex freelift for DCE 90-
140.
a) Lift the carriage about 0,5 m.
b) Connect a hose to the air vent valve. Put the other end on the
hose in a vessel.
008412

c) Open the valve and let the oil flow until the oil is free from air
bubbles flows out from the hose.

WARNING
The trolley lowers.

Risk of crushing.

15 Check the mast functions. Adjust the tilt cylinders as necessary,

please refer to Tilt cylinder, adjustment page 62.
16 Check the oil level in the hydraulic oil tank when all hydraulic pis-
tons are fully retracted. Top up as necessary.

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

 7 Load handling – 7.2.6 Mast 21

Flanges on outer and inner mast beam

page
–

Flanges on outer and inner mast beam, description

The mast and mast components is constructed out of high tension ma-
terials and is tested under heavy operation and enviroments for a long
and problem-free performance.
However problems due to neglected maintenance, heavy operation,
malfunction of mast wheels or damages to mast / fork carriage may oc-
cur. For example flatting or pitting of the beam flanges, mostly on the
inner mast but also on the outer mast.

Flanges on outer and inner mast beam, repair

If the surfaces have started breaking up in small flakes they can be
prepared so that the mast can be used again.Method starts with grind-
ing affected surface and continous with running in of surface.

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Remove the fork carriage from the mast, please refer to Fork car-
riage, removing page 35.
3 Remove the mast, please refer to Mast, removing page 16.
4 Divide the inner and and outer mast.
5 Remove mast wheels from inner mast.
6 Clean outer and inner mast.
7 Grind affected surfaces, with a belt grinder, to be smoth and
bright. Start with grain 36-40 and finish with grain 60-80.
185 mm / 245 mm

Grinding scratches shall run along beam direction

Check internal width between front and rear flange, if measure
exceeds 187 mm for 185 mm beam or 247 mm for 245 mm beam,
contact Cargotec.
8 Fit the mast wheels to the inner mast.
009543

9 Apply a thin layer of grease to running surfaces on the outer mast

and install inner mast to outer mast.
Beam size of 185 or 245 mm depending on type of 10 Apply a thin layer of grease to running surfaces on the inner mast
mast. and install mast to machine, please refer to Mast, installing page
19.
11 Install fork carriage into mast, please refer to Fork carriage, in-
stalling page 36.
12 Lift and lower mast to check function as follows:
Take a load of 6 ton for 185 mm beam or 8 ton for 245 mm beam
at stipulated CoG and run up and down 20 times.
Take a load of 10 ton for 185 mm beam or 12 ton for 245 mm
beam at stipulated CoG and run up and down 20 times.
Take max load at stipulated CoG and run up and down 20 times.
13 Check if running surfaces looks normal, if not, contact Cargotec.

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

22 7 Load handling – 7.2.7 Mast wheels

7.2.7 Mast wheels

Mast wheels, description
page
–

The mast wheels consist of a rim with one spherical roller bearing.

Adjustment of play for inner mast

page
–

1 Removing the fork carriage, please refer to Fork carriage, remov-

ing page 35.
2 It is possible to divide the mast when installed on the machine or
remove the mast, please refer to Mast, removing page 16 and di-
vide the mast on the ground.
3 Dividing the inner and outer mast.

Applies to Duplex standard

a) Undo cables, chains and hoses necessary for dividing the
mast, loosen the circlip attaching the lift cylinders to the inner
mast.
b) Connect lifting equipment to the inner mast, lift the inner mast
away from the outer mast.
c) Place the inner mast on the ground in a secure manner.
008602

Circlip attaching the lift cylinders

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

 7 Load handling – 7.2.7 Mast wheels 23

4 Check the mast wheels and replace as necessary.

5 Use a Vernier calliper to measure the internal width of the outer
mast.

B
008422

Measure internal width of outer mast (A and B)

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

24 7 Load handling – 7.2.7 Mast wheels

6 Use a Vernier calliper to measure the external width of the slide

plates (C and D).

014879

Mast with slide plates

D
014881

Mast with support rollers

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

 7 Load handling – 7.2.7 Mast wheels 25

7 Adjust the play.

a) If A and B is equal:
Adjust D to be equal to or max 0,5 mm less than B.
Adjust C to be equal to or max 0,5 mm less than D.
b) If A is larger than B:
Adjust D to be equal to or max 0,5 mm less than B.
Adjust C to be equal to or max 0,5 mm less than D.
c) If A is less than B:
Adjust D to be equal to or max 0,5 mm less than B.
Adjust C to be equal to or max 0,5 mm less than A.
8 Apply a thin layer of sliding grease to internal sliding surfaces of
014884 outer mast.
9 Lift the inner mast and slide the inner and outer mast together.

Mast with slide plates

014883

Mast with support rollers

Adjustment of play between upper support, in outer

page
–

mast, and inner mast

1 Apply a thin layer of sliding grease to external sliding surfaces of
inner mast.
2 Lower inner mast to bottom position.
3 Raise inner mast about 200 mm.

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

26 7 Load handling – 7.2.7 Mast wheels

4 Adjust upper support to touch outside of inner mast or give a play

of max 0,5 mm.
Use appropriate number of shims in rear and front end to give
alignment along the whole width of wear pad.
5 Lift inner mast to top position and check that wear pads not touch
to hard along beam.

008421

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

 7 Load handling – 7.2.7 Mast wheels 27

Adjustment of play between fork carriage and inner

page
–

mast
1 Removing the fork carriage, please refer to Fork carriage, remov-
ing page 35.

NOTE
Smaller adjutment of play between fork carriage and inner mast
is possible to perform without removing the fork carriage.
2 Check the mast wheels in the fork carriage and replace as nec-
essary.
3 Use a Vernier calliper to measure the internal width of the inner
mast.

B
008418

Measure internal width of inner mast (A and B)

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

28 7 Load handling – 7.2.7 Mast wheels

4 Use a Vernier calliper to measure the external width of the slide

plates/support rollers of the fork carriage.

D
014880

Mast with slide plates

D
014882

Mast with support rollers

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

 7 Load handling – 7.2.7 Mast wheels 29

5 Adjust the play by loosen the screw (position 1) and adding or re-
moving shim plates (position 2).
a) If A and B is equal:
Adjust C and D to be equal to or max 0,5 mm more than A.
b) If A is larger than B:
Adjust C to be equal to or max 0,5 mm more than A.
Adjust D to be equal to or max 0,5 mm more than B.
c) If A is less than B:
Adjust C to be equal to or max 0,5 mm more than A.
Adjust D to be equal to or max 0,5 mm less than B.
6 Apply a thin layer of sliding grease to internal sliding surfaces of
inner mast.
7 Install the fork carriage, see Fork carriage, installing page 36.
8 Lift the fork carriage to top position and check wear pads not
touch to hard along beam.
014009

Mast with slide plates

014013

Mast with support rollers

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

30 7 Load handling – 7.2.8 Chains

7.2.8 Chains
Chains, description
page
–

The chains are of the Fleyer chains type.

Chains, replacement
page
–

WARNING
The lifting chain is heavy.

Risk of crushing. The chain is difficult to handle.

Handle with caution and be very careful when the

chain is removed from the sprocket. Serious personal
injury and damage to the vehicle can result from care-
lessness.

1 Machine in service position, see section B Safety

2 Lower the load unit to the lowest position.
3 Release the lifting chain from the load unit.
Remove the pin and shaft from each side of the load unit.
4 Connect lifting equipment to the chain in a secure manner.
Undo the chain anchorage from the chain tensioner and lay the
chain down.
5 Fit a new chain.
008424

6 Tension the chains with the chain tensioners. Check that the
chains are tensioned equally.
7 Measure the ground clearance of the fork carriage. The distance
must be equal on the right and left sides, with a tolerance of ±5
mm. Adjust further with the chain tensioner if necessary.
008425

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 7 Load handling – 7.2.9 Chain wheels and hose wheels 31

7.2.9 Chain wheels and hose wheels

Chain wheels and hose wheels, description
page
–

The chain wheels and hose wheels are provided with two roller bear-
ings.

Chain wheels, replacement

page
–

1 Machine in service position, see section B Safety.

2 Raise the mast.
3 Put a support under the fork carriage and lower the mast again.
Chains and hoses are now slackened.
4 Connect lifting equipment to the chain in a secure manner.
Undo the chain anchorage from the chain tensioner and lay the
chain down.
5 Remove the hose guide that prevents the hoses from becoming
derailed.
1
6 Lift the hose off the hose wheel.
7 Undo the circlip and remove the hose wheel.

4
008426

1. Hose guide and attaching bolt

2. Hoses
3. Circlip ring
4. Hose wheel.
8 Undo the set screw that locks the shaft.
9 Pull the shaft out and remove the sprocket.

NOTE
The sprocket will fall down when the shaft is loosened!
10 Install a new sprocket and re-install the shaft.

NOTE
Lubricate the shaft with sliding grease.
11 Lock the shaft with the set screw.
12 Install the hose wheel.
13 Install the circlip.
14 Grease the sprocket.
15 Put the hoses back and install the hose guide.

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

32 7 Load handling – 7.2.9 Chain wheels and hose wheels

Chain wheels for freelift, replacement

–

1 Machine in service position, see section B Safety.

2 Raise the mast.
3 Put a support under the fork carriage and lower the mast again.
Chains and hoses are now slackened.
4 Connect lifting equipment to the chain in a secure manner.
Undo the chain anchorage from the chain tensioner and lay the
chain down.
5 Undo the set screw that locks the shaft.
6 Pull the shaft out and remove the sprocket.

NOTE
The sprocket will fall down when the shaft is loosened!
7 Install a new sprocket and re-install the shaft.

NOTE
Lubricate the shaft with sliding grease.
8 Lock the shaft with the set screw.

1 9 Grease the sprocket.

2 10 Re-install the chain.
008408

3
4
1. Shaft
2. Set screw
3. Bracket
4. Chain wheel

Hose wheels, replacement

page
–

1 Machine in service position, see section B Safety.

2 Raise the mast.
3 Put a support under the fork carriage and lower the mast again.
Chains and hoses are now slackened.

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

 7 Load handling – 7.2.9 Chain wheels and hose wheels 33

4 Remove the hose guide that prevents the hoses from becoming
derailed.
1
5 Lift the hose off the hose wheel.
6 Undo the circlip and remove the hose wheel.

2
NOTE
Lubricate the shaft with sliding grease.
3
7 Install a new hose wheel.
8 Install a circlip.
4 9 Put the hoses back and install the hose guide.

008426
1. Hose guide and attaching bolt
2. Hoses
3. Circlip ring
4. Hose wheel.
Hose wheels for Triplex freelift, replacement
–

1 Machine in service position, see section B Safety.

2 Raise the mast.
3 Put a support under the fork carriage and lower the mast again.
Chains and hoses are now slackened.
4 Undo the screw, pull out the shaft and remove the hose wheel.

NOTE
Lubricate the shaft with sliding grease.
5 Install a new hose wheel.
6 Re-install the shaft and lock it with the screw.

1
2
008407

3
4
1. Hose wheel
2. Bracket
3. Screw
4. Shaft

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

34 7 Load handling – 7.2.10 Fork carriage

7.2.10 Fork carriage

Fork carriage, description
page
–

A number of different fork carriages are available. The most common

version is with hydraulic side shift and fork spreading.
All fork carriage types work on the different masts, see Lift masts, de-
scription page 14.
The spreading-side shift carriage and center levelling carriage have
the same forks, while the carriage for manually adjusted forks and side
shift carriage have forks with different mountings, see Lift forks, de-
scription page 70.

A B

015471
C D E

A. Carriage for manually adjusted forks

B. Spreading-side shift carriage
C. Center levelling carriage
D. Side shift carriage

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

 7 Load handling – 7.2.10 Fork carriage 35

Fork carriage, removing

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Start the machine and set the mast vertical. Lower the mast.

NOTE
The fork carriage must be placed on a flat surface and se-
cured. It could otherwise tip over when the machine is re-
versed away.
2 Machine in service position, see section B Safety
3 Depressurize the hydraulic system, see section B Safety.
4 Mark and undo the hose connections to the fork carriage.

NOTE
Plug all connections at once to protect the hydraulic system
from contamination.
008427

5 Loosen the lifting chains in the vehicle.

008424

6 Hang weights on the chain to prevent them from running away

over the sprocket when the mast is raised.

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

36 7 Load handling – 7.2.10 Fork carriage

7 Start the machine and raise the mast, so that the fork carriage
comes loose. Reverse away from the mast, or move the fork car-
riage.

008428
Fork carriage, installing
page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Start the machine and set the mast vertical.
2 Hang weights on the chain to prevent them from running away
over the sprocket when the mast is raised.
3 Raise the mast so high that there is room for the fork carriage.

4 Fix the fork carriage on a traversing crane and drive the machine
towards the fork carriage, or put the fork carriage in place against
the mast.
5 Lower the mast.
6 Machine in service position, see section B Safety
7 Depressurize the hydraulic system, see section B Safety.
008428

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

 7 Load handling – 7.2.10 Fork carriage 37

8 Fix the chains in the fork carriage.

Install the shaft and lock it with a split pin.

008424
9 Tension the chains with the chain tensioners. Check that the
chains are tensioned equally.
10 Measure the ground clearance of the fork carriage. The distance
must be equal on the right and left sides, with a tolerance of ±5
mm. Adjust further with the chain tensioner if necessary.
008425

11 Connect the hydraulic hoses to the fork carriage in accordance

with the marking.

NOTE
Check that the O-rings are intact and fitted correctly.
12 Undo the lifting equipment (travelling crane).
13 Turn the main switch on and start the engine.
14 Activate the mast functions. Check that the hydraulic connections
seal correctly.
008427

15 Check the oil level in the hydraulic oil tank when all hydraulic pis-
tons are fully retracted. Top up as necessary.

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

38 7 Load handling – 7.2.11 Load control valve

7.2.11 Load control valve

Load control valve, description
page
–

The load control valves are located inside the bottom connection for
1 lifting cylinders for duplex standard mast and at the bottom for lift and
free-lift cylinders for duplex and triplex freelift masts.
The valve contains a spring-loaded guide piston and a moveable throt-
tle plate that work together to give a constant through-flow, regardless
2
of size of the load. The maximum lowering speed is constant and in-
3 dependent of the weight of the load.
For lifting, the throttle plate and the guide piston are in the through-flow
position, allowing the unobstructed passage of the oil. For lowering,
the throttle plate assumes a throttle position. The internal pressure
drop in the valve and the pre-load force of the guide piston's spring
005938

counteract each other, balancing the position of the guide piston, with
a corresponding size of restriction gap. Big load - small gap, small load
1. Lift cylinder - big gap.
2. Load control valve Duplex standard
3. Load control valve Duplex freelift, Triplex freelift

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

 7 Load handling – 7.2.12 Pipes and hoses 39

Load control valve, replacement

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety
2 Depressurize the hydraulic system, see section B Safety.
3 Detach the hydraulic hose from the load control valve.

NOTE
Plug the connection immediately to protect the hydraulic
system from impurities.
008414 4 Remove the connection adapter.

5 Undo the old load control valve with a flat blade screwdriver and
remove it.
6 Fit the new load control valve, (torque a 1” valve to 20 Nm).
7 Fit the connection adapter.
8 Connect the hydraulic hose to the adapter.

NOTE
Check that the O-rings are intact and fitted correctly.
9 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
10 Test the lifting and lower a couple of times checking max. lower-
ing speed with max load.
11 Check that the connections are sealed tightly.

7.2.12 Pipes and hoses

Pipes and hoses, description
page
–

See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

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

40 7 Load handling – 7.4 Side shift

7.4 Side shift

Side shift, function description (hydraulic servo)
page
–

6
8

C 4

3,5,7

PP
b

P2
B

PA

ACK2
TA

T1
C
P

9
T
A
a

2 2 2 C

1 1 1

007474
Pos Explanation Signal description Reference
1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.1
the hydraulic oil tank. left-hand front mud- Gear pump with fixed displacement
guard.

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group 10.6.8
High-pressure filter/Return filter

3 The accumulator charging valve directs - Section 10 Common hydraulics, group 10.5.2
oil to charging of the accumulator. Control valve

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group 10.3.2
left-hand front mud- Accumulator
guard.

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group 10.5.2
duces the pressure from hydraulic oil Control valve
pump 3 to servo pressure.

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

 7 Load handling – 7.4 Side shift 41

Pos Explanation Signal description Reference

6 Control lever, side shift, controls servo -
pressure in proportion to lever move-
ment to control valve load handling.

7 The servo pressure from control lever, - Main valve, description (hydraulic servo)
side shift, acts on the side shift slide in page 12
control valve, load handling, which
changes position and pressurizes the
side shift cylinders.

8 The oil pressurizes the shaft side of one - Main valve, description (hydraulic servo)
of the side shift cylinders. Oil is pressed page 12
out on the piston side.

9 Oil is directed into the piston side of the - -

other side shift cylinder. This presses
out oil on its shaft side and the forks are
moved sideways in parallel. Oil from the
side shift cylinder is directed back into
the tank.

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

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

42 7 Load handling – 7.4 Side shift

Side shift, function description (electrical servo)

page
–

Condition Reference value Reference

Control switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop voltage
(15E)

7 ECU796
6 D6
D7 10

8 3,5,9
b

P2
B

PA

ACK2
TA

T1
P
T
A
a

11
8
C

2 2 2 C

1 1 1

014835

Pos Explanation Signal description Reference

1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.1
the hydraulic oil tank. left-hand front mud- Gear pump with fixed displacement
guard.

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group 10.6.8
High-pressure filter/Return filter

3 The accumulator charging valve directs - Section 10 Common hydraulics, group 10.5.2
oil to charging of the accumulator. Control valve

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group 10.3.2
left-hand front mud- Accumulator
guard.

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

 7 Load handling – 7.4.1 Hydraulic oil pump 43

Pos Explanation Signal description Reference

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group 10.5.2
duces the pressure from hydraulic oil Control valve
pump 3 to servo pressure.

6 The control lever, side shift, (R8073) U = 0-10 V DC D6: Diagnostic menu, see section 8 Control
sends a voltage signal to Control unit hy- system, group 8.4.4.1 View inputs, menu 3,
draulics (ECU 796). ECU 796 input K1:11

7 The Control Unit Hydraulics (ECU 796), - Main valve, description (electrical servo)
sends a current signal to the solenoid page 12
valve for left-hand side shift (Y6020) or D7: Diagnostic menu, see section 8 Control
the solenoid valve for right -hand side system, group 8.4.4.2 View outputs, menu 1,
shift (Y6021). ECU 796 input K2:7 (left), input K2:8 (right)

8 Solenoid valve side shift left (Y6020) or - Main valve, description (electrical servo)
Solenoid valve side shift right (Y6021) page 12
controls servo pressure to the side shift
slide in control valve load handling.

9 The control valve’s side shift slide - Main valve, description (electrical servo)
changes position and pressurizes the page 12
side shift cylinders.

10 The oil pressurizes the shaft side of one - Side shift cylinder, description page 44
of the side shift cylinders. Oil is pressed
out on the piston side.

11 Oil is directed into the piston side of the - Side shift cylinder, description page 44
other side shift cylinder. This presses
out oil on its shaft side and the forks are
moved sideways in parallel. Oil from the
side shift cylinder is directed back into
the tank.

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

7.4.1 Hydraulic oil pump

Hydraulic oil pump, general
page
–

Please refer to section 10 Common hydraulics, group 10.4.1 Gear

pump with fixed displacement.

7.4.2 Accumulator
Accumulator, description
page
–

See section 10 Common hydraulics, group 10.3.2 Accumulator.

7.4.3 Main valve

Main valve, description (hydraulic servo)
page
–

Side shift is controlled by a separate section of the load handling con-

trol valve.

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

44 7 Load handling – 7.4.4 Side shift cylinder

For general information on the control valve, refer to section 10 Com-

mon hydraulics, group 10.5.2 Main valve.
For more information on side shift, see Side shift, function description
(hydraulic servo) page 40.

Side shift slide

When the side shift control lever is activated, pressure is applied to the
side shift spool, which controls the direction and flow of oil from the hy-
draulic oil pumps to the spreading cylinders. See Side shift cylinder,
description page 44.

Main valve, description (electrical servo)

page
–

Side shift is controlled by a separate section of the load handling con-

trol valve.
For general information on the control valve, refer to section 10 Com-
mon hydraulics, group 10.5.2 Main valve.
For more information on side shift, see Side shift, function description
(electrical servo) page 42.

Side shift slide

The side shift spool controls the direction and flow of oil to the side shift
cylinders.

Servo valve side shift left

On machines with electric servo, the servo valve for side shift left is
controlled electrically by Solenoid valve side shift left (Y6020), which
is activated by Control unit hydraulics (ECU 796). The servo valve ac-
tuates the servo pressure to the side shift spool. This pressure is pro-
portional to the control current to the solenoid valve.

Servo valve side shift right

On machines with electric servo, the servo valve for side shift right is
controlled electrically by Solenoid valve side shift right (Y6021), which
is activated by Control unit hydraulics (ECU 796). The servo valve ac-
tuates the servo pressure to the side shift spool. This pressure is pro-
portional to the control current to the solenoid valve.

7.4.4 Side shift cylinder

Side shift cylinder, description
page
–

The side shift cylinder (same cylinders used for spreading function, if
available) is provided with a pivot bearing at the cylinder end. The pis-
ton rod mounting is threaded to the piston rod.
The cylinder head is threaded in the cylinder barrel (and can be re-
moved using a hook wrench if needed).

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

 7 Load handling – 7.4.4 Side shift cylinder 45

Side shift cylinder, replacement

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Secure the side shift cylinder to the fork carriage with a strap.

3 Remove the shaft connecting the side shift cylinder to the fork.
Remove the screw and knock out the shaft.
4 Contract the side shift cylinder with the machine running.
5 Machine in service position, see section B Safety.
6 Depressurize the hydraulic system, see section B Safety.
7 Place a receptacle under the hydraulic hoses attached to the side
shift cylinder.
008429

8 Mark up and detach the hydraulic hoses from the side shift cylin-
der.

NOTE
Plug the connection immediately to protect the hydraulic
system from impurities.

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

46 7 Load handling – 7.4.5 Side shift frame

9 Remove the shaft connecting the side shift cylinder to the car-
riage. Remove the screw and pull out the shaft.
10 Transfer the connection adapters to the new side shift cylinder.
11 Fit the new side shift cylinder.
12 Fit the shafts and screws that connects the side shift cylinder to
the fork carriage and forks.
13 Connect the hydraulic hoses to the side shift cylinder in accord-
ance with the marking.

008430
NOTE
Check that the O-rings are intact and fitted correctly.
14 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
15 Test the side shift and spreading a couple of times.
16 Check that the connections are sealed tightly.

7.4.5 Side shift frame

Side shift frame, description
page
–

The side shift frame is the moveable part of the side shift carriage. The
side shift cylinder is attached to the frame as well as the carriage, and
thus provides the side shift movement.
See the image under Fork carriage, description page 34 (option D).

7.4.6 Fork carriage

Fork carriage, description
page
–

See Fork carriage, description page 34.

7.4.7 Pipes and hoses

Pipes and hoses, description
page
–

See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

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

 7 Load handling – 7.5 Spreading 47

7.5 Spreading
Spreading, function description (hydraulic
page
–

servo)

6
9
8
C 4

3,5,7 9

PP
b

P2
B

PA

ACK2
TA

T1
C
P
T
A
a

2 2 2 C

1 1 1

007476
Pos Explanation Signal description Reference
1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.1
the hydraulic oil tank. left-hand front mud- Gear pump with fixed displacement
guard.

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group 10.6.8
High-pressure filter/Return filter

3 The accumulator charging valve directs - Section 10 Common hydraulics, group 10.3.5
oil to charging of the accumulator. Accumulator charging valve, description

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group 10.3.2
left-hand front mud- Accumulator
guard.

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group 10.5.2
duces the pressure from hydraulic oil Control valve
pump 3 to servo pressure.

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

48 7 Load handling – 7.5 Spreading

Pos Explanation Signal description Reference

6 Control lever, spreading, controls servo -
pressure in proportion to lever move-
ment to control valve load handling.

7 The servo pressure from control lever, - Main valve, description (hydraulic servo)
spreading, acts on the spreading slide in page 12
control valve, load handling, which
changes position and pressurizes the
spreading cylinders.

8 Spread inwards - Section 10 Common hydraulics, group 10.4.1

The flow distributor checks that the oil Gear pump with fixed displacement
volume supplied to the piston sides of
each cylinder is equal.
Spread outwards
The flow distributor checks that the oil
volume that comes from the piston sides
of each cylinder is equal.

9 The spread cylinders move the forks - Spreading cylinder, description page 53
sideways.

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

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

 7 Load handling – 7.5 Spreading 49

Spreading, function description (electrical

page
–

servo)

Condition Reference value Reference

Control switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop voltage
(15E)

ECU796
7
6 D6 11
D7 10

8 3,5,9 11

PP
b

P2
B

PA

ACK2
TA

T1
P
T
A
a

8
C

2 2 2 C

1 1 1

014836
Pos Explanation Signal description Reference
1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.1
the hydraulic oil tank. left-hand front mud- Gear pump with fixed displacement
guard.

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group 10.6.8
High-pressure filter/Return filter

3 The accumulator charging valve directs - Section 10 Common hydraulics, group 10.3.5
oil to charging of the accumulator. Accumulator charging valve, description

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group 10.3.2
left-hand front mud- Accumulator
guard.

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

50 7 Load handling – 7.5.1 Hydraulic oil pump

Pos Explanation Signal description Reference

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group 10.5.2
duces the pressure from hydraulic oil Control valve
pump 3 to servo pressure.

6 The control lever, spreading (R8074) U = 0-10 V DC D6: Diagnostic menu, see section 8 Control
sends a voltage signal to the Control system, group 8.4.4.1 View inputs, menu 3,
Unit Hydraulics (ECU 796). ECU 796 input K1:12

7 The Control Unit Hydraulics (ECU 796), - Main valve, description (electrical servo)
sends a current signal to the solenoid page 51
valve for inwards spread (Y6019) or the D7: Diagnostic menu, see section 8 Control
solenoid valve for outwards spread system, group 8.4.4.2 View outputs, menu 2,
(Y6018). ECU 796 input K2:12 (in), input K2:11 (out)

8 The solenoid valve for inwards spread - Main valve, description (electrical servo)
(Y6019) or the solenoid valve for out- page 51
wards spread (Y6018) controls servo
pressure to the spread slide in control
valve load handling.

9 The control valve’s spread slide chang- - Spreading cylinder, description page 53
es position and pressurizes the spread
cylinders.

10 Spread inwards - Flow divider, description page 52

The flow distributor checks that the oil
volume supplied to the piston sides of
each cylinder is equal.
Spread outwards
The flow distributor checks that the oil
volume that comes from the piston sides
of each cylinder is equal.

11 The spread cylinders move the forks - Spreading cylinder, description page 53
sideways.

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

7.5.1 Hydraulic oil pump

Hydraulic oil pump, description
page
–

Please refer to section 10 Common hydraulics, group 10.4.1 Gear

pump with fixed displacement.

7.5.2 Accumulator
Accumulator, description
page
–

See section 10 Common hydraulics, group 10.3.2 Accumulator.

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

 7 Load handling – 7.5.3 Main valve 51

7.5.3 Main valve

Main valve, description
page
–

See section 10 Common hydraulics, group 10.5.2 Main valve.

Main valve, description (hydraulic servo)

page
–

Spreading is controlled by a separate section of the main valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information on spreading, see Spreading, function descrip-
tion (hydraulic servo) page 47.

Spreading slide
When the spreading control lever is activated, pressure is applied to
the spreading spool, which controls the direction and flow of oil from
the hydraulic oil pumps to the side shift cylinders. See Spreading cyl-
inder, description page 53.

Main valve, description (electrical servo)

page
–

Spreading is controlled by a separate section of the main control valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information on spreading, see Spreading, function descrip-
tion (electrical servo) page 49.

Servo valve spreading out

The servo valve for spreading out is controlled electrically by Solenoid
valve spreading out (Y6018), which is activated by Control unit hy-
draulics (ECU 796). The servo valve actuates the servo pressure to
the spreading spool. This pressure is proportional to the control cur-
rent to the solenoid valve.

Servo valve spreading in

The servo valve for spreading in is controlled electrically by Solenoid
valve spreading in (Y6019), which is activated by Control unit hydrau-
lics (ECU 796). The servo valve actuates the servo pressure to the
spreading spool. This pressure is proportional to the control current to
the solenoid valve.

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

52 7 Load handling – 7.5.4 Flow divider

7.5.4 Flow divider

Flow divider, description
page
–

The flow divider is a pressure-compensated valve that synchronizes

the forks' movements during fork spreading. The valve divides the flow
from the main valve in two equal parts, regardless of the load on the
two connected cylinders.
The difference between pressures P1 and P2 behind the respective
control slide balances the slides producing the correct sizes of control
gap. When the flow goes the other way, the valve combines the flows
by each connected cylinder contributing equal flow to the common re-
turn.
1
000678

1. Flow divider

Flow divider, replacement

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic system, see section B Safety.
3 Place a container under the flow divider to collect oil waste.
4 Mark up and detach the hydraulic hoses from the flow divider.

NOTE
Plug the connections immediately to protect the hydraulic
system from impurities.
5 Remove the two bolts that secure the flow divider to the carriage.
6 Remove the flow divider.
7 Transfer the connection adapters to the new flow divider.
8 Fit the new flow divider.
008431

9 Connect the hydraulic hoses to the flow divider in accordance

with the marking.

NOTE
Check that the O-rings are intact and fitted correctly.
10 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
11 Test the spreading a couple of times.
12 Check that the flow divider's connections are sealed tightly.

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

 7 Load handling – 7.5.5 Spreading cylinder 53

7.5.5 Spreading cylinder

Spreading cylinder, description
page
–

See Side shift cylinder, description page 44.

7.5.6 Fork carriage

Fork carriage, description
page
–

See Fork carriage, description page 34.

7.5.7 Pipes and hoses

Pipes and hoses, description
page
–

See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

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

54 7 Load handling – 7.7 Tilt

7.7 Tilt
Tilt, function description (hydraulic servo)
page
–

9
C 4

3, 5, 7

PP

b
P2
PA

B
ACK2
TA
8 9
VB C1

T1
VA C2

C
P
T

A
a

2 2 2 C

1 1 1

Pos Explanation Signal description Reference 007472

1 The hydraulic oil pumps pumps oil from See pressure plate on Section 10 Common hydraulics, group
the hydraulic oil tank. left-hand front mudguard. 10.4.1 Gear pump with fixed displacement

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group

10.6.8 High-pressure filter/Return filter

3 The accumulator charging valve in the - Section 10 Common hydraulics, group

valve block directs oil to charging of the 10.5.2 Control valve
accumulator.

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group
left-hand front mudguard. 10.3.2 Accumulator

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group
duces the pressure from hydraulic oil 10.5.2 Control valve
pump 3 to servo pressure.

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

 7 Load handling – 7.7 Tilt 55

Pos Explanation Signal description Reference

6 Control lever, tilt, controls servo pres- -
sure in proportion to lever movement to
control valve load handling.

7 The servo pressure from control lever, - Main valve, description (hydraulic servo)
tilt, acts on the tilt slide in control valve, page 12
load handling, which changes position
and pressurizes the tilt cylinders.

8 Tilt in - Load control valve, description page 38

The oil is pressed in via the load holding
valve to the tilt cylinders’ shaft side. Oil
is evacuated from the piston sides of the
cylinders via the load holding valve and
the control valve, back to the tank.
Tilt out
The oil is pressed in via the load holding
valve to the tilt cylinders’ piston side.
From the shaft sides of the cylinders, the
oil is evacuated to the load holding
valve. This provides back pressure in
the return line. This way unwanted tilt
out is avoided which would otherwise
occur with the combination of heavy
load and high lifting height. Oil is moved
from the load holding valve via the con-
trol valve to the tank

9 The tilt cylinders angle the mast in rela- - Tilt cylinder, description page 60
tion to the frame. Lift masts, description page 14

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

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

56 7 Load handling – 7.7 Tilt

Tilt, function description (electrical servo)

page
–

Condition Reference value Reference

Control switch Disengaged Section 11 Common electrics, group 11.5.1.4
Emergency stop voltage (15E)

7 ECU796
6 D7
D6
11
4 8
3, 5, 9

P2
PA

B
ACK2
TA

10 11
VB C1

T1
VA C2

C
P

A
T

2 2 2

1 1 1

014837

Pos Explanation Signal description Reference

1 The hydraulic oil pumps pumps oil from See pressure plate on Section 10 Common hydraulics, group
the hydraulic oil tank. left-hand front mudguard. 10.4.1 Gear pump with fixed displacement

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group

10.6.8 High-pressure filter/Return filter

3 The accumulator charging valve in the - Section 10 Common hydraulics, group

valve block directs oil to charging of the 10.5.2 Control valve
accumulator.

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group
left-hand front mudguard. 10.3.2 Accumulator

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

 7 Load handling – 7.7 Tilt 57

Pos Explanation Signal description Reference

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group
duces the pressure from hydraulic oil 10.5.2 Control valve
pump 3 to servo pressure.

6 The control lever tilt (R8072) sends a U = 0-10 V DC D6: Diagnostic menu, see section 8 Control
voltage signal which is proportional to system, group 8.4.4.1 View inputs, menu 3,
the lever movement to the Control Unit ECU 796 input K1:10
Hydraulics (ECU 796).

7 The Control Unit Hydraulics (ECU 796), - Main valve, description (electrical servo)
sends a current signal to the solenoid page 12
valve for tilt out (Y6010) or the solenoid D7: Diagnostic menu, see section 8 Control
valve for tilt in (Y6011). system, group 8.4.4.2 View outputs, menu
1, ECU 796 input K2:5 (tilt out), input K2:6
(tilt in)

8 Solenoid valve for tilt out (Y6010) or the - Main valve, description (electrical servo)
solenoid valve for tilt in (Y6011) allo- page 12
cates servo pressure in proportion to the
control current to the tilt slide in control
valve load handling.

9 The control valve tilt slide changes posi- - Main valve, description (electrical servo)
tion and pressurizes the tilt cylinders. page 12

10 Tilt in - Load control valve, replacement page 39

The oil is pressed in via the load holding
valve to the tilt cylinders’ shaft side. Oil
is evacuated from the piston sides of the
cylinders via the load holding valve and
the control valve, back to the tank.
Tilt out
The oil is pressed in via the load holding
valve to the tilt cylinders’ piston side.
From the shaft sides of the cylinders, the
oil is evacuated to the load retention
valve. This provides back pressure in
the return line. This way unwanted tilt
out is avoided which would otherwise
occur with the combination of heavy
load and high lifting height. Oil is moved
from the load holding valve via the con-
trol valve to the tank.

11 The tilt cylinders angle the mast in rela- - Tilt cylinder, description page 60
tion to the frame. Lift masts, description page 14

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

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

58 7 Load handling – 7.7.1 Hydraulic oil pump

7.7.1 Hydraulic oil pump

Hydraulic oil pump, description
page
–

Please refer to section 10 Common hydraulics, group 10.4.1 Gear

pump with fixed displacement.

7.7.2 Accumulator
Accumulator, description
page
–

See section 10 Common hydraulics, group 10.3.2 Accumulator.

7.7.3 Main valve

Main valve, description (hydraulic servo)
page
–

Tilting is controlled by a separate section of the main valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information about tilting, see Tilt, function description (hy-
draulic servo) page 54.

Tilt slide
When the tilt control lever is activated, pressure is fed to the tilt spool,
which controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.

Main valve, description (electrical servo)

page
–

Tilt is controlled by a separate section of the main valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information about tilting, see Tilt, function description (elec-
trical servo) page 56.

Tilt slide
When the servo valves are activated, pressure is fed to the tilt spool,
which controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.

Servo valve tilt out

On machines with electric servo, the servo valve for tilt out is controlled
electrically by Solenoid valve tilt out (Y6010), which is activated by
Control unit hydraulics (ECU 796). The servo valve actuates the servo
pressure to the tilt spool. This pressure is proportional to the control
current to the solenoid valve.

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

 7 Load handling – 7.7.4 Load holding valve (over-centre valve) 59

Servo valve tilt in

On machines with electric servo, the servo valve for tilt in is controlled
electrically by Solenoid valve tilt in (Y6011), which is activated by Con-
trol unit hydraulics (ECU 796). The servo valve actuates the servo
pressure to the tilt spool. This pressure is proportional to the control
current to the solenoid valve.

7.7.4 Load holding valve (over-centre

valve)
Load holding valve, description
page
–

The load holding valve is integrated in the distribution block on the

front plate of the chassis.
The valve's task is to produce a back-pressure in the return line from
the tilt cylinders. In this way, undesired forward tilt is avoided, which
would otherwise result for the combination of a heavy load and high
lifting height. Tilting becomes smoother as a result of the load holding
2 valve.
1 In this case, the load holding valve is set to 160 bar. A load that gives
a pressure of 100 bar requires 20 bar in the pilot line, which is connect-
ed to the other end of cylinder, for the load holding valve to release oil
at a pilot ratio of 1:3. This is somewhat simplified since the 20 bar in
the cylinder's other end also gives a pressure increase in the end that
001906

is connected to the load holding valve.

1. Distribution block
2. Load holding valve

Load holding valve, replacement

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic system, see section B Safety.
3 Mark up and detach the hydraulic hoses from the load holding
valve.

NOTE
Plug the connections immediately to protect the hydraulic
system from impurities.
008432

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60 7 Load handling – 7.7.5 Tilt cylinder

4 Remove the two bolts that secure the load holding valve to the
chassis.
5 Remove the load holding valve.
6 Fit the new load holding valve.
7 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.

008433
8 Test the tilt a couple of times.
9 Check that the load holding valve's connection are sealed tightly.

7.7.5 Tilt cylinder

Tilt cylinder, description
page
–

The tilt cylinder is provided with double attaching eyes at the cylinder
end. The piston rod mounting is threaded to the piston rod and is
locked with screws and lock plates.
The tilt cylinder is attached to the outer mast and to the front plate of
the frame.
The cylinder head is threaded in the cylinder barrel (and can be re-
moved using a hook wrench if needed).
001910

Tilt cylinder, replacement

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Tilt the mast forward.
2 Machine in service position, see section B Safety.
3 Depressurize the hydraulic system, see section B Safety.
4 Connect lifting equipment to the lifting lugs on the mast in a se-
cure manner.
5 Secure the tilt cylinder to an overhead crane.
6 Place a container under the hose connections on the tilt cylinder
to collect oil waste.
7 Mark and undo the hydraulic connections to the tilt cylinder.

NOTE
Plug all connections at once to protect the hydraulic system
008412

from contamination.

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 7 Load handling – 7.7.5 Tilt cylinder 61

8 Release the tilt cylinder from the mast and frame.

1
Remove the screws that holds the lock plate for the cylinder
shafts.
9 Remove the cylinder shafts. If necessary, use a slide hammer to
drive the shafts out.
10 Remove the tilt cylinder.
2
11 Transfer the connection adapters to the new tilt cylinder.
12 Connect the new tilt cylinder.
Install the cylinder shafts

008415
NOTE
1. Cylinder shaft
Check that the bearings in the cylinder anchorages are cor-
2. Screw and washer
rectly aligned before the cylinder shafts are installed.
Rotate the shaft to find correct position for the lock plate.
Mount the lock plate and secure with the two screws.
Repeat the procedure for the other cylinder.
13 Grease the cylinder anchorages.
14 Connect the hydraulic hoses to the tilt cylinder in accordance with
the marking.

NOTE
Check that the O-rings are intact and fitted correctly.
15 Undo the lifting equipment (travelling crane).
16 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
17 Test the tilt a couple of times.
18 Check that the tilt cylinders’ connections are sealed tightly.
19 Check the tilt function. Adjust the new tilt cylinder as necessary,
please refer to Tilt cylinder, adjustment page 62

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

62 7 Load handling – 7.7.6 Mast

Tilt cylinder, adjustment

page
–

During tilting in or out, the mast should stop solidly and not be twisted.
If the mast is twisted, the tilt cylinders must be adjusted to make their
stroke equal.
1 Tilt the mast so that the cylinders are half extended.
2 Machine in service position, see section B Safety.
3 Undo the screws.
4 Turn the piston rod with a hook spanner.
5 Check that the cylinder strokes are equal in length.
6 Check the tilt function. Repeat the adjustment until the tilt function
operates correctly.
7 Install the screws.
008594

Hydraulic cylinders, repairing

page
–

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

7.7.6 Mast
Lift masts, description
page
–

See Lift masts, description page 14.

7.7.7 Pipes and hoses

Pipes and hoses, description
page
–

See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

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 7 Load handling – 7.8 Levelling 63

7.8 Levelling
Levelling, function description (hydraulic servo)
page
–

6
C

3,5,7

PP
b

P2
B

PA

ACK2
TA

T1
8

C
A

P
T
a

2 2 2 C

1 1 1

007478
Pos Explanation Signal description Reference
1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.1
the hydraulic oil tank. left-hand front mud- Gear pump with fixed displacement
guard.

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group 10.6.8
High-pressure filter/Return filter

3 The accumulator charging valve directs - Section 10 Common hydraulics, group 10.5.2
oil to charging of the accumulator. Control valve

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group 10.3.2
left-hand front mud- Accumulator
guard.

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group 10.5.2
duces the pressure from hydraulic oil Control valve
pump 3 to servo pressure.

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

64 7 Load handling – 7.8 Levelling

Pos Explanation Signal description Reference

6 Control lever, levelling, controls servo -
pressure in proportion to lever move-
ment to control valve load handling.

7 The servo pressure from control lever, - Main valve, description (hydraulic servo)
levelling, acts on the levelling slide in page 67
control valve, load handling, which
changes position and pressurizes the
levelling cylinder.

8 Levelling fork upwards - Levelling cylinder, description page 68

Oil is directed to the piston side of the
levelling cylinder and evacuated from its
shaft side via the control valve, back to
the tank.
Levelling fork downwards
Oil is directed to the shaft side of the lev-
elling cylinder and evacuated from its
piston side via the control valve, back to
the tank.

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

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

 7 Load handling – 7.8 Levelling 65

Levelling, function description (electrical servo)

page
–

Condition Reference value Reference

Control switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop voltage
(15E)

7 ECU796
D6
6 D7

8 3,5,9

P2
B

PA

ACK2
TA

T1
10
A

P
T

C 8

2 2 2 C

1 1 1

Pos Explanation Signal description Reference 014838

1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.1
the hydraulic oil tank. left-hand front mud- Gear pump with fixed displacement
guard.

2 High-pressure filter cleans the oil. - Section 10 Common hydraulics, group 10.6.8
High-pressure filter/Return filter

3 The accumulator charging valve directs - Section 10 Common hydraulics, group 10.5.2
oil to charging of the accumulator. Control valve

4 The accumulator stores pressure. See pressure plate on Section 10 Common hydraulics, group 10.3.2
left-hand front mud- Accumulator
guard.

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

66 7 Load handling – 7.8.1 Hydraulic oil pump

Pos Explanation Signal description Reference

5 A reduction valve in the valve block re- P = 3.5 MPa Section 10 Common hydraulics, group 10.5.2
duces the pressure from hydraulic oil Control valve
pump 3 to servo pressure.

6 Control lever levelling (R8075) sends U = 0-10 V DC D6: Diagnostic menu, see section 8 Control
voltage signal to Control unit hydraulics system, group 8.4.4.1 View inputs, menu 3,
(ECU 796). ECU 796 input K1:13

7 The Control Unit Hydraulics (ECU 796), - Main valve, description (electrical servo)
sends a current signal to the solenoid page 67
valve for downwards levelling (Y6022) D7: Diagnostic menu, see section 8 Control
or the solenoid valve for upwards level- system, group 8.4.4.2 View outputs, menu 2,
ling (Y6023). ECU 796 input K2:13 (down), input K2:14
(up)

8 The solenoid valve for downwards level- - Main valve, description (electrical servo)
ling (Y6022) or the solenoid valve for up- page 67
wards levelling (Y6023) controls servo
pressure to the levelling slide in control
valve load handling.

9 The control valve’s levelling slide chang- - Main valve, description (electrical servo)
es position and pressurizes the levelling page 67
cylinders.

10 Levelling fork upwards - Levelling cylinder, description page 68

Oil is directed to the piston side of the
levelling cylinder and evacuated from its
shaft side via the control valve, back to
the tank.
Levelling fork downwards
Oil is directed to the shaft side of the lev-
elling cylinder and evacuated from its
piston side via the control valve, back to
the tank.

Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics

7.8.1 Hydraulic oil pump

Hydraulic oil pump, description
page
–

Please refer to section 10 Common hydraulics, group 10.4.1 Gear

pump with fixed displacement.

7.8.2 Accumulator
Accumulator, description
page
–

See section 10 Common hydraulics, group 10.3.2 Accumulator.

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 7 Load handling – 7.8.3 Main valve 67

7.8.3 Main valve

Main valve, description (hydraulic servo)
page
–

Levelling is controlled by a separate section of the main valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information about levelling, see Levelling, function descrip-
tion (hydraulic servo) page 63.

Levelling slide
When the levelling control lever is activated, pressure is fed to the lev-
elling spool, which controls the direction and flow of oil from the hy-
draulic oil pumps to the fork levelling cylinder.

Main valve, description (electrical servo)

page
–

Levelling is controlled by a separate section of the main valve.

For general information on the main valve, refer to section 10 Common
hydraulics, group 10.5.2 Main valve.
For more information about levelling, see Levelling, function descrip-
tion (electrical servo) page 65.

Levelling slide
When the servo valves are activated, pressure is fed to the tilt spool,
which controls the direction and flow of oil from the hydraulic oil pumps
to the fork levelling cylinder.

Servo valve levelling down

On machines with electric servo, the servo valve for tilt out is controlled
electrically by Solenoid valve fork levelling down (Y6022), which is ac-
tivated by Control unit hydraulics (ECU 796). The servo valve actuates
the servo pressure to the tilt spool. This pressure is proportional to the
control current to the solenoid valve.

Servo valve levelling up

On machines with electric servo, the servo valve for tilt in is controlled
electrically by Solenoid fork levelling up (Y6023), which is activated by
Control unit hydraulics (ECU 796). The servo valve actuates the servo
pressure to the tilt spool. This pressure is proportional to the control
current to the solenoid valve.

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

68 7 Load handling – 7.8.4 Levelling cylinder

7.8.4 Levelling cylinder

Levelling cylinder, description
page
–

The levelling cylinder is provided with double attaching eyes at the cyl-
inder end. The piston rod mounting is threaded to the piston rod and is
locked with lock bolts and lock plate.
If the machine has levelling forks, the levelling cylinder is attached to
the fork and the fork levelling guide in the carriage.
If the machine has a center levelling carriage, the two levelling cylinder
are attached to the inner and outer carriage on either side.
The cylinder head is threaded in the cylinder barrel (and can be re-
moved using a hook wrench if needed).

Levelling cylinder, replacement

page
–

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety
2 Remove the screw that is holding the rod end of cylinder in the
fork carriage.
3 Contract the cylinder with the machine running so that rod goes
into the cylinder.
4 Machine in service position, see section B Safety.
5 Depressurize the hydraulic system, see section B Safety.
6 Mark and undo the hydraulic connections to the levelling cylinder.

NOTE
Plug all connections at once to protect the hydraulic system
from contamination.
7 Remove the split pin and the shaft that is holding the cylinder in
the fork.
8 Remove the levelling cylinder.
9 Transfer the connection adapters to the new levelling cylinder.
10 Connect the new levelling cylinder.
Install the cylinder shaft and split pin holding the cylinder to the
fork.
Install the screw holding the cylinder to the fork carriage.
11 Connect the hydraulic hoses to the levelling cylinder in accord-
ance with the marking.

NOTE
Check that the O-rings are intact and are fitted correctly.
12 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
13 Test the levelling a couple of times.
14 Check that the levelling cylinders’ connections are sealed tightly.

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

 7 Load handling – 7.8.5 Fork carriage 69

Hydraulic cylinders, repairing

page
–

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

7.8.5 Fork carriage

Fork carriage, description
page
–

See Fork carriage, description page 34.

7.8.6 Levelling fork

Levelling fork, description
page
–

The levelling fork can be manoeuvred up and down through the action
of the levelling cylinder. The fork runs through a sleeve for up and
down movements. See Lift forks, description page 70.

7.8.7 Pipes and hoses

Pipes and hoses, description
page
–

See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

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

70 7 Load handling – 7.9 Load carrier

7.9 Load carrier

7.9.1 Lift forks
Lift forks, description
page
–

The forks are fully forged of high-strength steel. The standard mount-
ing, with manually adjusted forks, is with hooks on the fork carriage.
The hydraulically maneuverable forks are mounted on bearing-
equipped rollers, four rollers at the top and two support rollers at the
bottom on each fork.

A B

C D E

000830
A. Manually adjustable forks
B. Spreading-side shift forks
C. levelling fork as well as fork with timber support.
D. Fork carrier
E. Fork for fork carrier

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 7 Load handling – 7.9.1 Lift forks 71

Lift forks, replacement

page
–

1 Machine in service position, see section B Safety.

2 Remove the shaft connecting the spreading cylinder to the fork.
Remove the screw and knock out the shaft.

3 Remove the four screws that secure the bracket for the spreading
cylinder.
4 Place a hand truck under the fork for support.

5 Pull out the fork to the side along the carriage.

Secure the lift fork in a suitable way so that it does not tip.
6 Replace the fork.
7 Fit in the reverse order.

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

72 7 Load handling – 7.10 Other functions

7.10 Other functions

7.10.1 Electric scales
Scales, description
page
–

Machine can be installed with two different scale functions:

1. Electric-hydraulic scales that do not display anything to the driver,
but can be used by other functions in the machine. A pressure
sensor in the lift cylinder measures the pressure and so estimates
the weight of the load.
2. Electric scales, which use a load cell sensor in the two chain ten-
sioners and measures weight with higher precision and in the
main display screen showing the weight in 0,1 ton resolution, giv-
ing a more direct interface with the driver.
With the electric scales there are two load cells in the chain tightener
with built-in amplifier that gives the weight of the load. The accuracy
depends on mast movement before measuring. The scales and load
sensors are very sensitive and are affected by several factors such as
friction in the mast and fork carriage, oil temperature and bearings.
The mast should be in a vertical position and the fork carriage centred.
Under these conditions the load sensors in the chain tightener function
optimally. The fork carriage should be raised and then lowered to
about 1 metre above the ground before calibration and weighing. If the
system is calibrated after gentle lowering, and weighing is performed
in the same way, then an accuracy of about 1% of the maximum load
capacity is achieved. The weight is presented continuously on the dis-
play, in tonnes to one decimal place (e.g. 5.2 tonnes).

Scales, calibration
page
–

The scales on a machine equipped with complete scales are always

adjusted and calibrated from the factory. For correct use of the scales
they must be calibrated regularly against a known test weight.

NOTE
The mast should be in a vertical position and the fork carriage
should be centred for weighing, calibration and taring.

1 Operate the trolley up and down a few times to remove any me-
chanical tension.
2 Operate the machine for a few minutes before zero adjustment
and weight calibration take place.
3 To select the function to calibrate, first navigate to the service
menu. Then press Enter.
000056

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

 7 Load handling – 7.10.1 Electric scales 73

4 Enter the code for calibration.

The code is obtained from Cargotec Support.
1 23
4 5 NOTE

000060
The code determines which service menu shall be activated
(Diagnostics, Initiation or Calibration).
5 Select SCALE by scrolling with the arrow keys (1 and 2) and con-
firm with Enter.
SCALE

000803

6 Unload, operate the trolley up and lower it slowly to about 1 metre

CALIBR 1(2) above the ground. Reset to zero by pressing in the
600 menu 1 (2).
SCALE 600
WITHOUT LOAD (mV)
000804

7 Load with a known weight (preferably a frequently used loading

CALIBR 2(2) weight or close to the machine’s maximum load), adjust with 4

4000 8000 KG
4000 8000 KG and 5 to the correct weight and lower the trolley slightly. Con-
SCALE WITH LOAD firm the weight by pressing in the menu 2 (2). For the weight
000805

to be adjustable there must be a value in setup for maximum lift

capacity.

Function test
–

If scale is calibrated load using an arbitrary weight (another weight

than that used when calibrating) and read the display. Does this cor-
respond to the weight?

Trouble shooting
–

Error/malfunction symptoms:
• If error code 304 is generated all the time, then check the output
voltage from the load cells. The summed voltage souldn't be be-
low 0.2V.

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

74 7 Load handling – 7.10.2 Pre-selected lift height

7.10.2 Pre-selected lift height

Pre-selected lift height, description
page
–

When the lifting height is selected the driver activates the lift and lower
function to move the forks (or attachment) to the selected height.
When the forks approach the selected lifting height the lift or lower
speed is reduced. Note that the lever must be activated by the driver
during the whole movement. The system ensures that the forks stop
at the correct lifting height. (Pre-selection can also be switched on or
off by pressing the switch by the lifting lever). The current position, ON
or OFF is indicated in the display. End position damping at lowest and
highest lifting height provides gentle stops.

Function test
–

Operate the forks / bale clamp to about 100 mm (4”) and read the lifting
height into “Lifting height 1” by holding 4 and 5 in for 1 second.
Continue this procedure with “lifting height 2 - 15” with increased mast
height. “Lifting height 15” should be close to the machine’s highest lift-
ing height.
Lower to the lowest height. Select an arbitrary height. The display
shows “ON”. Pull the lift lever and check that the forks / bale clamp
stop gently at the selected lifting height. The display shows “OFF”. Do
the same test with a load.
Do the same test when the selected lifting height is below the current
lifting height, i.e. the load is lowered to the selected height. Do this test
with and without load as well.

Trouble shooting
–

All alarms are saved and can be read out according to “Last alarms”.
This may be of great value when troubleshooting a machine that, ac-
cording to the operator/test, has had problems, but that aren’t trig-
gered when troubleshooting.
For error code tables, see section D Error codes.

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 7 Load handling – 7.10.3 Vertical alignment 75

7.10.3 Vertical alignment

Vertical alignment, description
page
–

A B
The vertical alignment function constantly attempts to hold the load
vertical. The system is load compensating and also takes into consid-
eration the downward pitch of the machine when a load is picked up
or deposited. Load compensation takes place after lift and lower is
concluded. Instead of the driver needing to seek vertical orientation
manually, it takes place automatically via pressing the switch by the tilt
lever.

002487
Vertical alignment is switched off by pressing the switch or activating
the tilt lever.

A. Lever for tilt Kalmar’s vertical alignment function uses a tilt angle sensor located
B. Switch for vertical alignment between the mast and frame, and a pressure sensor in the lifting cyl-
inder, which also serves as a scale to weigh the load. If electronic
scales are installed, they are used.
With load and without load, deviation of the tilt angle is only +/- 1 de-
gree with the load in lowest position. For example, with 6000 mm lift
height, the tilt angle deviation is +/- 2 degrees with and without load in
the attachment.
An orange lamp located on the stand or steering wheel panel indicates
the status of the vertical alignment.

Lamp extinguished Vertical alignment shut off

Flashing lamp The vertical alignment adjusts the mast to the
vertical position.
Lamp lit The load is aligned vertically.

Function test
–

Check that the vertical position is achieved with different loads. The
stand should move slowly, with gentle starting and stopping.

Trouble shooting
–

All alarms are saved and can be read out according to “Last alarms”.
This may be of great value when troubleshooting a machine that, ac-
cording to the operator/test, has had problems, but that aren’t trig-
gered when troubleshooting.
For error code tables, see section D Error codes.

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76 7 Load handling – 7.10.4 Optimum lift

7.10.4 Optimum lift

Optimum lift, description
page
–

Optimum lift optimises lift speed in relation to engine speed, load and
lifting lever deflection when the machine is operated under a fixed set
speed limit. This results in a higher lift speed, lower sound level, lower
fuel consumption and reduced exhaust emissions during load
handling.
The function intelligently controls a variable pump in relation to engine
speed, current load and the lifting lever’s position when lifting. The
pump is load sensing, which only allows the oil quantity (flow) and the
pressure required in each step to be added to the flow and pressure
that the fixed pump supplies. The variable pump operates in parallel
with the fixed pump. This means that the lift speed can be increased
significantly (up to 60%).
Optimum lift is activated when engine speed exceeds a lower adjust-
able limit (e.g. 1000 rpm), the machine’s speed is below 8 km/h and
the position of the lifting lever fulfils set limit values.
Depending on the value from the load sensor, control unit (ECU 790)
reduces the pump’s displacement linearly in order to prevent the en-
gine being overloaded. The engine speed is limited to an upper adjust-
able limit in order to use the engine’s torque more efficiently.

7.10.5 Side lift attachment

Side lift attachment, description
page
–

Component supplier documentation

The workshop manual only describes components and job descrip-
tions related to installation in the machine. Please refer to the compo-
nent supplier documentation for descriptions and instructions of the
side lift attachments components and systems.
References to component supplier documentation are only provided in
exceptional cases. If information about a component is not found, the
component supplier documentation should be used.

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 8 Control system 1

8 Control system

Table of Contents 8 Control system

mm mm mm mm mm mm

8 Control system ............................................................................................... 3

8.2 Monitoring ................................................................................................... 4
8.2.3 Speed limitation ..................................................................................... 4
8.3 Error codes ................................................................................................. 5
8.4 Diagnostics ................................................................................................. 6
8.4.1 ECU 790 ................................................................................................ 9
8.4.2 ECU 792 .............................................................................................. 15
8.4.3 ECU 793 .............................................................................................. 18
8.4.4 ECU 796 .............................................................................................. 18
8.4.5 Last alarms .......................................................................................... 25
8.5 Setup ........................................................................................................ 28
8.5.1 ETC-Electronic Throttle Control (electronic throttle) ............................ 28
8.5.2 Automatic shifting ................................................................................ 30
8.5.4 Feedback lever steering ...................................................................... 35
8.5.5 NON feedback lever steering ............................................................... 40
8.5.6 Mini-wheel ............................................................................................ 40
8.5.7 Electro-hydraulic servo ........................................................................ 42
8.5.8 Scale .................................................................................................... 48
8.5.9 Monitoring ............................................................................................ 48
8.5.10 Pre-selected lifting height .................................................................... 49
8.5.11 Tilt control ............................................................................................ 50
8.5.12 OptimumLift ......................................................................................... 51
8.5.14 Clamp and lift function/lower and open function .................................. 53
8.5.15 Automatic clamping function ................................................................ 54
8.5.16 Protection against loose chain tension ................................................ 56
8.5.17 Protection against inadvertent opening of the clamp ........................... 56
8.5.18 Automatic lowering stop ....................................................................... 57
8.5.19 Driving interlock ................................................................................... 57
8.5.20 Speed limitation related to lift height .................................................... 57
8.5.21 Reversible driver’s station .................................................................... 57
8.6 Software ................................................................................................... 59
8.6.1 Kalmar Smart Link ............................................................................... 59

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2 8 Control system

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 8 Control system – 8 Control system 3

8 Control system
mm mm mm mm mm mm

Control system, general

page
–

Many of the machines functions are controlled electrically. The signals

that control the machine are monitored to warn the operator or limit the
machine's functions in certain dangerous situations or in case of ma-
chine malfunctions.
The control system is divided into the following functions:
• Monitoring functions
• Error codes
• Diagnostics
• Setup
• Software
Monitoring functions describe the machine’s monitoring functions that
warn the operator or limit the machine’s functions in case of eventual
dangerous situations.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostics is tool for performing service and troubleshooting with
menus in the machine’s display.
Setup is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

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4 8 Control system – 8.2 Monitoring

8.2 Monitoring
8.2.3 Speed limitation
Speed limitation, description
page
–

Speed limitation prevents the machine’s road speed from exceeding

the set speed by limiting the engine speed.
Machine speed is limited when:
• constant speed limitation is set.
• conditional speed limitation is activated and there is 0 V on the
digital input in ECU790 K1:16 to conditional speed limitation.

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 8 Control system – 8.3 Error codes 5

8.3 Error codes

Error codes, description
page
–

When a malfunction occurs in the machine error messages (error

codes) are generated by the control unit in question that is sending the
error code via the CAN-bus to Control unit display (EDU795) that
shows the error codes on the display and stores the error codes.
Explanation of error codes is available in section D Error codes.

Error code indication

An error code is indicated by a lit indicator for active error codes (po-
1 2 sition 2). Error codes are classified into three levels based on severity.
The error code levels are indicated as follows:
• STOP is indicated with a STOP sign on the display, together with
continuous red light from the indicator control system (position 2).
Error code with level Stop is shown automatically on the display.
B
• Warning is indicated by a warning triangle in the display together
with a steady red glow from the indicator for the control system
(position 2).
Error code with level Warning is shown automatically on display.
• Information is indicated by a spanner in the display together with
a constant red light from the indicator for the control system (po-
sition 2).
Error code with level Information is shown automatically in the dis-
play.
009450

B. Error code level symbol

1. Display control system, KCS
2. Indicator control system, KCS

Error code display

Error code information is shown with display figures and symbols that
307 indicate what error has occurred.
The error codes and images can be temporarily removed using the
Reset (R) function key, at which time they disappear from the display.
If the error code is active, it reappears in the display within 1-3 min-
004257

utes.

Example figure, automatic display figure

NOTE
If error code disappears automatically, it may be due to the fol-
lowing:
– the fault that generated the error code is no longer active,
e.g. the sensor has a loose connection and causes poor con-
nection.

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6 8 Control system – 8.4 Diagnostics

8.4 Diagnostics
Diagnostics, general
page
–

The machine can be delivered in different electrical versions and using

the schematics, display and a diagnostic display, all ECU 790, ECU
792, ECU 793 and ECU 796 inputs and outputs can be diagnosed.
The machine has integrated functions for troubleshooting (diagnos-
tics). The diagnostics comprises several menus presented in the dis-
DIAGNOSTICS play. The menus are grouped according to control unit for faster
access. The following pages describe the menu images’ contents and
000916 what functions can be checked.
The diagnostics is divided into the following groups:
• Control unit, ECU 790, ECU 790, diagnostic description page 9.
• Control unit, ECU 792, ECU 792, diagnostic description page 15.
• Control unit, ECU 793, ECU 793, diagnostic description page 18.
• Control unit, ECU 796, ECU 796, diagnostic description page 18.
• Error codes history, Last alarms, description page 25.
In this section the different diagnosis menus included in the control
system, KCS, are explained.
The values stated in the following menus are relevant examples
(standard values) of what can be in these positions. The actual value
can deviate from these examples.

Diagnostics, description
–

The diagnostics varies between the different control units as to what

type of diagnostics can be carried out, but the following alternatives
are possible:
• View inputs – means that the inputs can be checked (digital and
analogue).
• View outputs – means that the outputs can be checked (digital and
analogue).
• Control outputs – means that the outputs can be checked and
controlled (digital and analogue).

NOTE
The application program closes due to safety reasons when
controlling outputs. Control O/P is only possible with service
code.

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 8 Control system – 8.4 Diagnostics 7

Diagnostics, example
–

If there is a problem with the lifting function then this can be resolved
using the wiring diagram and/or PIN-out (connections), to see which
input and output on the control unit (ECU) the function is using. See
section E Schematics, group 11 Common electrical and section 11
Common electrical, group 11.5.3 Control units.
The input value from a lever is shown in the diagnostic menus (e.g.
mV). The ECU dedicated output current to the valve can be viewed
and a check if the ECU software want to control the valve. It can be
quickly ascertained whether the problem is on the in or output side and
if the control unit is working properly without connecting to other instru-
ments.
This way the diagnosis can quickly be made for all functions in the con-
trol system.
With appropriate authority the outputs can also be controlled using a
service code. When this is carried out the application program is
closed (not possible to run as normal) as long as the “Control Output”
menu is selected and the red indicators (position 2) are flashing. The
deactivation of the application programme enables “forced operation”
of the functions connected to the control unit.

Diagnostics, work instruction

–

To select diagnostics, proceed as follows:

1 Navigate to the service menu using 1 and 2 .

2 Select the service menu using function key .

000056

3 A safety menu appears where users must state a code to access

the diagnosis menus.

1 23 State code for diagnostics (11111).

4 5
000060

4 Select diagnostics by pressing .

DIAGNOSTICS
000916

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8 8 Control system – 8.4 Diagnostics

5 Main selection for diagnostics now shown on display.

Choose which control unit shall be investigated using the function
DIAGNOSTICS ECU790
keys 1 and 2 and confirm with .
Only accessible control units on the machine are displayed.

DIAGNOSTICS ECU792 Each diagnostic function comprises a sequence of a number of

diagnosis menus. The first diagnosis menu for selected diagnos-
tic group appears in the display. Choose the next diagnosis menu
using and .
DIAGNOSTICS ECU793
1 2

DIAGNOSTICS ECU796

LAST ALARMS
008576

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 8 Control system – 8.4.1 ECU 790 9

8.4.1 ECU 790

ECU 790, diagnostic description
page
–

Select diagnostics as per Diagnostics, work instruction page 7.

Select diagnostics for ECU 790. This display indicates whether ECU
790 is selected. Press function key to proceed.
DIAGNOSTICS ECU 790

000918
The following alternatives can be selected in the diagnostics for ECU
DIAG ECU 790 1(3) 790:
1. View inputs
VIEW INPUTS 2. View outputs
3. Control outputs

DIAG ECU 790 2(3) Scroll forwards to required menu using the function keys 1 and

VIEW OUTPUTS 2 and press to confirm.

DIAG ECU 790 3(3)

CONTROL OUTPUTS
002844

8.4.1.1 View inputs

View inputs, description
page
–

Select View inputs for ECU 790 as per ECU 790, diagnostic descrip-
tion page 9.
1 Check digital input for ECU 790.
DIGITAL IN 1(7) 1:09 involves contact 1, pin 9 on ECU 790. The box is filled if the
1:09 1:13 input voltage is > 12V. The box is empty if the voltage is < 5V.
1:10 1:14 This applies to all digital inputs.
1:11 1:15
008496

1:12 1:16

2 Check digital input for ECU 790 further.

DIGITAL IN 2(7)
1:17 1:21
1:18 1:22
1:19 1:23
008497

1:20

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10 8 Control system – 8.4.1.2 View outputs

3 Check temperature input for ECU 790. (Unconnected tempera-

ture input indicates -35.2 °C.)
Check rheostat input in ohm (2:08).

008498
4 Check analogue input for ECU 790. Measurement range: 0.00–
ANALOGUE IN (V) 4(7) 5.50V.
1:01 24.88 1:26 0.54
1:07 24.88 1:27 0.55
1:08 24.88 1:28 2.43
1:24 5.00 1:29 4.41 008499

5 Check analogue input for ECU 790 further.

ANALOGUE IN (V) 5(7)
1:30 1.34 1:34 0.54
1:31 2.30 1:37 0.01
1:32 1.62 1:38 0.55
008500

1:33 0.53 1:39 0.02

6 Check analogue input for ECU 790 further.

ANALOGUE IN (V) 6(7)

1:40 0.01
1:41 0.01
008501

1:42 0.01

7 Check frequency input for ECU 790. Measurement range:

FREQUENCY IN 7(7) 0.5 Hz–10 kHz.

2:01 2 Hz
2:03 697 Hz
008502

2:05-06 0 PULSES

8.4.1.2 View outputs

View outputs, description
page
–

Select View outputs for ECU 790 as per ECU 790, diagnostic descrip-
tion page 9.
1 Check digital output for ECU 790.
DIGITAL OUT 1(4)
2:10 2:14 2:10 means contact 2, pin 10 on ECU 790. The box is filled if the
2:11 2:15 voltage on the output is approx. 24V (active). The box is empty if
2:12 2:29 the output is 0V (not active).
008503

2:13 2:38

2 Check digital output for ECU 790 further (for example contact 2,
DIGITAL OUT 2(4) pin 41).
2:39
2:40
2:41
008577

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 8 Control system – 8.4.1.4 Control outputs 11

3 Check analogue PWM output for ECU 790. The current on the
ANALOGUE OUT(mA) 3(4) output is indicated in mA.
2:23 0 2:27 0
2:24 0 2:28 0
2:25 0

000930
2:26 0

4 Check analogue 20-80% of analogue outputs dedicated to Sauer

ANALOGUE OUT 4(4) Danfoss PVG valves, contact 2:30 and 2:31.
2:30 8%
2:31 8

008504
8.4.1.4 Control outputs
Control outputs, description
page
–

WARNING
When the outputs are controlled directly from the ter-
minal, this can seriously affect machine performance.

Only accredited personnel, with sufficient knowledge

of the machine and the control system, must there-
fore use these menus.

The engine must be shut off if the test does not re-
quire otherwise.

NOTE
The application program closes due to safety reasons when
checking outputs. Control O/P is only possible with service code.
Select Control outputs for ECU 790 as per ECU 790, diagnostic de-
scription page 9.
1 Control digital output for ECU 790.
CONTROL OUTPUT 1(19) 2:10 means contact 2, pin 10 on ECU 790. The box is filled if the
voltage on the output is approx. 24V (active). The box is empty if
2:10
the output is 0V (not active). Using the output can be
008505

ON/OFF = ENTER switched between approx. 24V (active, ON) and 0V (not active,
OFF).
2 Control digital output for ECU 790 further.
CONTROL OUTPUT 2(19)

2:11
008506

ON/OFF = ENTER

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12 8 Control system – 8.4.1.4 Control outputs

3 Control digital output for ECU 790 further.

CONTROL OUTPUT 3(19)

2:12

008507
ON/OFF = ENTER

4 Control digital output for ECU 790 further.

CONTROL OUTPUT 4(19)

2:13
008508
ON/OFF = ENTER

5 Control digital output for ECU 790 further.

CONTROL OUTPUT 5(19)

2:14
008509

ON/OFF = ENTER

6 Control digital output for ECU 790 further.

CONTROL OUTPUT 6(19)

2:15
008510

ON/OFF = ENTER

7 Control digital output for ECU 790 further.

CONTROL OUTPUT 7(19)

2:29
008511

ON/OFF = ENTER

8 Control digital output for ECU 790 further.

CONTROL OUTPUT 8(19)

2:38
008512

ON/OFF = ENTER

9 Control digital output for ECU 790 further.

CONTROL OUTPUT 9(19)

2:39
008513

ON/OFF = ENTER

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 8 Control system – 8.4.1.4 Control outputs 13

10 Control digital output for ECU 790 further.

CONTROL OUTPUT 10(19)

2:40

008514
ON/OFF = ENTER

11 Control digital output for ECU 790 further.

CONTROL OUTPUT 11(19)

2:41

008515
ON/OFF = ENTER

12 Control PWM output for ECU 790.

CONTROL OUTPUT 12(19) In this and the following menus the actual-value is next to the out-
put pin designation and the set-value (what is required, adjusted
2:23 0 mA
value) is on the row below.
ADJUST (+/-) 0 mA
008516

ON/OFF = ENTER Using 4 and 5 the required current can be adjusted. ON/OFF
confirmed with .
13 Control PWM output for ECU 790 further.
CONTROL OUTPUT 13(19)

2:24 0 mA
ADJUST (+/-) 0 mA
008517

ON/OFF = ENTER

14 Control PWM output for ECU 790 further.

CONTROL OUTPUT 14(19)

2:25 0 mA
ADJUST (+/-) 0 mA
008518

ON/OFF = ENTER

15 Control PWM output for ECU 790 further.

CONTROL OUTPUT 15(19)

2:26 0 mA
ADJUST (+/-) 0 mA
008519

ON/OFF = ENTER

16 Control PWM output for ECU 790 further.

CONTROL OUTPUT 16(19)

2:27 0 mA
ADJUST (+/-) 0 mA
008520

ON/OFF = ENTER

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14 8 Control system – 8.4.1.4 Control outputs

17 Control PWM output for ECU 790 further.

CONTROL OUTPUT 17(19)

2:28 0 mA
ADJUST (+/-) 0 mA

008521
ON/OFF = ENTER

18 Control analogue output for Sauer Danfoss PVG valves, 20 –

CONTROL OUTPUT 18(19) 80% of main voltage. Starts at 50%.

2:30 0% Adjust the out signal using 4 and 5 .

ADJUST (+/-) 0%
ON/OFF = ENTER 008522 ON/OFF confirmed with

19 Control analogue output for ECU 790 further, 20–80% of main

CONTROL OUTPUT 19(19) voltage. Starts at 50%.

2:31 0%
ADJUST (+/-) 0%
008523

ON/OFF = ENTER

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 8 Control system – 8.4.2 ECU 792 15

8.4.2 ECU 792

ECU 792, diagnostic description
page
–

Select diagnostics as per Diagnostics, work instruction page 7.

Select diagnostics for ECU 792. This display indicates whether ECU
792 is selected. Press function key to proceed.
DIAGNOSTICS ECU 792

008524
The following alternatives can be selected in the diagnostics for ECU
DIAG ECU 792 1(3) 792:
1. View inputs
VIEW INPUTS 2. View outputs
3. Control outputs

DIAG ECU 792 2(3) Scroll forwards to required menu using the function keys 1 and

VIEW OUTPUTS 2 and press to confirm.

DIAG ECU 792 3(3)

CONTROL OUTPUTS
008525

8.4.2.1 View inputs

View inputs, description
page
–

Select View inputs for ECU 792 as per ECU 790, diagnostic descrip-
tion page 9.
1 Check digital input for ECU 792.
DIGITAL IN 1(5) 1:02 involves contact 1, pin 2 on ECU 792. The box is filled if the
1:02 input voltage is > 12V. The box is empty if the voltage is < 5V.
1:03 This applies to all digital inputs.
1:04
008526

1:05

2 Check analogue input for ECU 792. Measurement range: 0.00–

ANALOGUE IN 2(5) 5.00V.
1:06 0.55V
1:07 1.54V
1:08_10 310mA
008527

1:09_11 550mA

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16 8 Control system – 8.4.2.2 View outputs

3 Check analogue input for ECU 792 further. Measurement range:

ANALOGUE IN 3(5) 0.00–5.00V.
1:14 4.54V
1:23_33 200mA
1:25_34 300mA

008528
1:28_42 400mA

4 Check analogue input for ECU 792 further. Measurement range:

ANALOGUE IN 4(5) 0.00–5.00V.
1:31 1.08V
1:32 2.89V
1:35 3.75V
1:36 4.99V 008529

5 Check frequency input for ECU 792. Measurement range:

FREQUENCY IN 5(5) 0.5 Hz–10 kHz.
1:16 120 Hz
1:17 250 Hz
1:18 1340 Hz
008530

1:19 3490 Hz

8.4.2.2 View outputs

View outputs, description
page
–

Select View outputs for ECU 792 as per ECU 790, diagnostic descrip-
tion page 9.
1 Check digital output for ECU 792.
DIGITAL OUT 1(2)
1:40 1:40 means contact 1, pin 40 on ECU 792. The box is filled if the
voltage on the output is approx. 24V (active). The box is empty if
008531

1:41
the output is 0V (not active).

2 Check analogue PWM output for ECU 792. The current on the
ANALOGUE OUT 2(2) output is indicated in mA.
1:06 220 1:26 580
1:07 275 1:27 590
1:22 600
008532

1:24 340

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 8 Control system – 8.4.2.4 Control outputs 17

8.4.2.4 Control outputs

Control outputs, description
page
–

WARNING
When the outputs are controlled directly from the ter-
minal, this can seriously affect machine performance.

Only accredited personnel, with sufficient knowledge

of the machine and the control system, must there-
fore use these menus.

The engine must be shut off if the test does not re-
quire otherwise.

NOTE
The application program closes due to safety reasons when
checking outputs. Control O/P is only possible with service code.
Select Control outputs for ECU 792 as per ECU 790, diagnostic de-
scription page 9.
1 Control digital output for ECU 792.
CONTROL OUTPUT 1(8) 1:40 means contact 1, pin 40 on ECU 792. The box is filled if the
voltage on the output is approx. 24V (active). The box is empty if
1:40
the output is 0V (not active). Using the output can be
008533

ON/OFF = ENTER switched between approx. 24V (active, ON) and 0V (not active,
OFF).
2 Control digital output for ECU 792 further.
CONTROL OUTPUT 2(8)

1:41
008534

ON/OFF = ENTER

3 Control PWM output for ECU 792.

CONTROL OUTPUT 3(8) In this and the following menus the actual-value is next to the out-
put pin designation and the set-value (what is required, adjusted
1:06 350
value) is on the row below.
ADJUST (+/-) 350
008535

ON/OFF = ENTER Using 4 and 5 the required current can be adjusted. ON/OFF
confirmed with .
4 Control PWM output for ECU 792 further.
CONTROL OUTPUT 4(8)

1:07 340
ADJUST (+/-) 340
008536

ON/OFF = ENTER

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18 8 Control system – 8.4.3 ECU 793

5 Control PWM output for ECU 792 further.

CONTROL OUTPUT 5(8)

1:22 200
ADJUST (+/-) 200

008537
ON/OFF = ENTER

6 Control PWM output for ECU 792 further.

CONTROL OUTPUT 6(8)

1:24 450
ADJUST (+/-) 450
008538
ON/OFF = ENTER

7 Control PWM output for ECU 792 further.

CONTROL OUTPUT 7(8)

1:26 580
ADJUST (+/-) 580
008539

ON/OFF = ENTER

8 Control PWM output for ECU 792 further.

CONTROL OUTPUT 8(8)

1:27 470
ADJUST (+/-) 470
008540

ON/OFF = ENTER

8.4.3 ECU 793

ECU 793, diagnostic description
page
–

Select diagnostics as per Diagnostics, work instruction page 7.

Select diagnostics for ECU 793. This display indicates whether ECU
793 is selected. Press function key to proceed.
DIAGNOSTICS ECU 793
Display shows a reflection of the display in ECU 793 when it is in diag-
nostics mode. see section 8 Control system; 2 Transmission, group
000954

2.8 Control system, transmission.

008541

8.4.4 ECU 796

ECU 796, diagnostic description
page
–

Select diagnostics as per Diagnostics, work instruction page 7.

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 8 Control system – 8.4.4.1 View inputs 19

Select diagnostics for ECU 796. This display indicates whether ECU
796 is selected. Press function key to proceed.
DIAGNOSTICS ECU 796

000955
The following alternatives can be selected in the diagnostics for
ECU 796:
DIAG ECU 796 1(3)
1. View inputs
VIEW INPUTS 2. View outputs
3. Control outputs

DIAG ECU 796 2(3) Scroll forwards to required menu using the function keys 1 and
2 and press to confirm.
VIEW OUTPUTS

DIAG ECU 796 3(3)

CONTROL OUTPUTS
002843

8.4.4.1 View inputs

View inputs, description
page
–

Select View inputs for ECU 796 as per ECU 796, diagnostic descrip-
tion page 18.
1 Check digital input for ECU 796.
DIGITAL 1(5) 1:30 means contact 1, pin 30 on ECU 796. The box is filled if the
1:30 1:34 voltage in is > 12V. The box is empty if the voltage is < 5V. This
1:31 1:35 applies for all digital inputs.
1:32 1:36
008542

1:33 1:37

2 Check digital and temperature input for ECU 796. (Unconnected

temperature input indicates -35.0 °C.)
008543

3 Check analogue input for ECU 796. Measurement range: 0.00–

ANALOGUE (V) 3(5) 10.00V.
1:1 24.88 1:10 0.54
1:7 24.88 1:11 0.55
1:8 24.38 1:12 2.43
008544

1:9 5.00 1:13 4.41

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20 8 Control system – 8.4.4.2 View outputs

4 Check analogue input for ECU 796 further.

ANALOGUE (V) 4(5)
1:16 1.34 1:20 0.54
1:17 2.30 1:21 0.01
1:18 1.62 1:22 0.55

008545
1:19 0.53 1:23 0.02

5 Check analogue input for ECU 796 further.

ANALOGUE (V) 5(5)
1:24 5.00 2:9 0.01
1:25 1.34 3:9 0.01
1:27 0.55
008546
1:29 4.41

8.4.4.2 View outputs

View outputs, description
page
–

Select View outputs for ECU 796 as per ECU 796, diagnostic descrip-
tion page 18.
1 Check analogue output K2 for ECU 796.
ANALOGUE (mA) 1(4) 2:10 means contact 2 (K2), pin 10 on ECU 796. The box is filled
2:10 2:5 0 if the voltage on the output is approx. 24V (active). The box is
2:6 0 empty if the output is 0V (not active).
2:3 0 2:7 0
000963

2:4 0 2:8 0 On output 2:3 etc. current displayed in mA.

2 Check analogue output K2 for ECU 796 further.

ANALOGUE (mA) 2(4)

2:11 0 2:14 0
2:12 0 2:15 0
000964

2:13 0 2:16 0

3 Check analogue output K3 for ECU 796.

ANALOGUE (mA) 3(4) This and the next menu are displayed only if ECU has 24 ana-
3:10 3:5 0 logue outputs (standard is 12). These outputs are then in connec-
3:6 0 tor 3, K3.
3:3 0 3:7 0
000965

3:4 0 3:8 0

4 Check analogue output K3 for ECU 796 further.

ANALOGUE (mA) 4(4)

3:11 0 3:14 0
3:12 0 3:15 0
000966

3:13 0 3:16 0

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 8 Control system – 8.4.4.4 Control outputs 21

8.4.4.4 Control outputs

Control outputs K2, description
page
–

WARNING
When the outputs are controlled directly from the ter-
minal, this can seriously affect machine performance.

Only accredited personnel, with sufficient knowledge

of the machine and the control system, must there-
fore use these menus.

The engine must be switched off if the test does not

require otherwise.

NOTE
The application program closes due to safety reasons when
checking outputs. Control O/P is only possible with service code.
Select Control outputs for ECU 796 as per ECU 796, diagnostic de-
scription page 18.
1 Control analogue output K2 for ECU 796.
CONTROL OUTPUT 1(13) 2:10 means contact 2 (K2), pin 10 on ECU 796. The box is filled
if the voltage on the output is approx. 24V (active). The box is
2:10
empty if the output is 0V (not active). Using the output can be
000967

ON/OFF = ENTER switched between approx. 24V (active, ON) and 0V (not active,
OFF).
2 Control analogue output K2 for ECU 796 further.
CONTROL OUTPUT 2(13) In this and the following menus the actual-value (the set value) is
next to the output pin designation and the set-value (what is re-
2:3 0 mA quired, adjusted value) is on the row below.
ADJUST (+/-) 0 mA
000968

ON/OFF = ENTER Using 4 and 5 the required current can be adjusted. ON/OFF
confirmed with .
3 Control analogue output K2 for ECU 796 further.
CONTROL OUTPUT 3(13)

2:4 0 mA
ADJUST (+/-) 0 mA
000969

ON/OFF = ENTER

4 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 4(13)

2:5 0 mA
ADJUST (+/-) 0 mA
000970

ON/OFF = ENTER

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22 8 Control system – 8.4.4.4 Control outputs

5 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 5(13)

2:6 0 mA
ADJUST (+/-) 0 mA

000971
ON/OFF = ENTER

6 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 6(13)

2:7 0 mA
ADJUST (+/-) 0 mA
000972
ON/OFF = ENTER

7 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 7(13)

2:8 0 mA
ADJUST (+/-) 0 mA
000973

ON/OFF = ENTER

8 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 8(13)

2:11 0 mA
ADJUST (+/-) 0 mA
000974

ON/OFF = ENTER

9 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 9(13)

2:12 0 mA
ADJUST (+/-) 0 mA
000975

ON/OFF = ENTER

10 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 10(13)

2:13 0 mA
ADJUST (+/-) 0 mA
000976

ON/OFF = ENTER

11 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 11(13)

2:14 0 mA
ADJUST (+/-) 0 mA
000977

ON/OFF = ENTER

12 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 12(13)

2:15 0 mA
ADJUST (+/-) 0 mA
000978

ON/OFF = ENTER

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 8 Control system – 8.4.4.4 Control outputs 23

13 Control analogue output K2 for ECU 796 further.

CONTROL OUTPUT 13(13)

2:16 0 mA
ADJUST (+/-) 0 mA

000979
ON/OFF = ENTER
Control outputs K3, description
–

WARNING
When the outputs are controlled directly from the ter-
minal, this can seriously affect machine performance.

Only accredited personnel, with sufficient knowledge

of the machine and the control system, must there-
fore use these menus.

The engine must be switched off if the test does not

require otherwise.

NOTE
The application program closes due to safety reasons when
checking outputs. Control O/P is only possible with service code.
Select Control outputs for ECU 796 as per ECU 796, diagnostic de-
scription page 18.
1 Control analogue output K3 for ECU 796.
CONTROL OUTPUT 1(13) This and the following menu are displayed only if ECU has 24 an-
alogue outputs (standard is 12). These outputs are then in con-
3:10 nector 3, K3.
000980

ON/OFF = ENTER

2 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 2(13)

3:3 0 mA
ADJUST (+/-) 0 mA
000981

ON/OFF = ENTER

3 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 3(13)

3:4 0 mA
ADJUST (+/-) 0 mA
000982

ON/OFF = ENTER

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24 8 Control system – 8.4.4.4 Control outputs

4 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 4(13)

3:5 0 mA
ADJUST (+/-) 0 mA

000983
ON/OFF = ENTER

5 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 5(13)

3:6 0 mA
ADJUST (+/-) 0 mA
000984
ON/OFF = ENTER

6 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 6(13)

3:7 0 mA
ADJUST (+/-) 0 mA
000985

ON/OFF = ENTER

7 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 7(13)

3:8 0 mA
ADJUST (+/-) 0 mA
000986

ON/OFF = ENTER

8 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 8(13)

3:11 0 mA
ADJUST (+/-) 0 mA
000987

ON/OFF = ENTER

9 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 9(13)

3:12 0 mA
ADJUST (+/-) 0 mA
000988

ON/OFF = ENTER

10 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 10(13)

3:13 0 mA
ADJUST (+/-) 0 mA
000989

ON/OFF = ENTER

11 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 11(13)

3:14 0 mA
ADJUST (+/-) 0 mA
000990

ON/OFF = ENTER

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 8 Control system – 8.4.5 Last alarms 25

12 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 12(13)

3:15 0 mA
ADJUST (+/-) 0 mA

000991
ON/OFF = ENTER

13 Control analogue output K3 for ECU 796 further.

CONTROL OUTPUT 13(13)

3:16 0 mA
ADJUST (+/-) 0 mA

000992
ON/OFF = ENTER

8.4.5 Last alarms

Last alarms, description
page
–

A history of the latest error codes generated can be seen under this
menu. If the same error code is generated several times this is count-
ed and the number of faults is shown on the display. Time and date is
shown when the error code was generated.
Select diagnostics and Last alarms as per Diagnostics, work instruc-
tion page 7. This display indicates if Last alarms is selected. Press
LAST ALARMS function key to proceed.
The 10 latest error codes are displayed in chronological order (with er-
000995

ror code number), number of error codes and the respective time and
date for the last error code of this type received.
If only one error code is saved there is only the menu for that fault and
the last menu “Clear all alarms”. So the number of menus under Last
alarms is dynamic. Max. number of error codes saved is 10.
1 Latest active error codes (1, latest) in chronological order.
LAST ALARMS 1(13)
ALARM NUMBER 354
COUNTER 11
16.01.2007 10:58
009350

2 Latest active error codes (2) in chronological order.

LAST ALARMS 2(13)
ALARM NUMBER 358
COUNTER 8
16.01.2007 10:58
009351

3 Latest active error codes (3) in chronological order.

LAST ALARMS 3(13)
ALARM NUMBER 361
COUNTER 3
16.01.2007 10:58
009352

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26 8 Control system – 8.4.5 Last alarms

4 Latest active error codes (4) in chronological order.

LAST ALARMS 4(13)
ALARM NUMBER 364
COUNTER 2
16.01.2007 10:58

009353
5 Latest active error codes (5) in chronological order.
LAST ALARMS 5(13)
ALARM NUMBER 380
COUNTER 6
16.01.2007 10:58 009354

6 Latest active error codes (6) in chronological order.

LAST ALARMS 6(13)
ALARM NUMBER 384
COUNTER 1
16.01.2007 10:58
009355

7 Latest active error codes (7) in chronological order.

LAST ALARMS 7(13)
ALARM NUMBER 601
COUNTER 3
16.01.2007 10:58
009356

8 Latest active error codes (8) in chronological order.

LAST ALARMS 8(13)
ALARM NUMBER 610
COUNTER 1
16.01.2007 10:58
009357

9 Latest active error codes (9) in chronological order.

LAST ALARMS 9(13)
ALARM NUMBER 900
COUNTER 1
16.01.2007 10:58
009358

10 Latest active error codes (10) in chronological order.

LAST ALARMS 10(13)
ALARM NUMBER 1200
COUNTER 2
16.01.2007 10:58
009359

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 8 Control system – 8.4.5 Last alarms 27

11 Latest active error codes (11) for the engine. more than one code,
LAST ALARMS 11(13) scroll the error codes by pressing the (+) function key.
ENGINE ALARM 1(X)
SPN: 110
FMI: 10

009360
PRESS (+) FOR NEXT
12 Latest active error codes (12) for the gearbox. more than one
LAST ALARMS 12(13) code, scroll the error codes by pressing the (+) function key.
GEARBOX ALARM 1(X) Dana TE13000/17000 don't support this.
SPN: 5490
FMI: 11
009361
PRESS (+) FOR NEXT
13 Clear all error codes (possible only with service code). This menu
13(13) is shown if there is one or more error codes. To clear all error
CLEAR ALL ALARMS? codes, press on function key (Yes = ).
YES = ENTER
Dana TE13000/17000 and Volvo TAD650VE/TAD750VE don't
009362

support this.

Shown if no saved error codes exist and after reset. If no error codes
13(13) from the KCS-system is present, only menus 11-13 is shown.

NO ALARMS
009364

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28 8 Control system – 8.5 Setup

8.5 Setup
Setup, description
page
–

The setup menus are used to initiate and calibrate the different func-
tions.
Initiation means basic setting of the parameters for the different func-
tions. Calibration means individual adjustment of the values for max.
and min. of the signals for the different functions. This section de-
scribes how to proceed with initiation and calibration of respective
function.
The number of menu pages per function can vary depending on the
functions with which the machine’s control system is equipped. Thus,
the total number of menus is dynamic.
The values included in certain menus are relevant examples (guide-
line values) of what may appear in these positions. The real value may
differ from these examples.

8.5.1 ETC-Electronic Throttle Control

(electronic throttle)
ETC, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Electronic Throttle Control.

ELECTRONIC THROTTLE
(Scroll to the desired menu with function keys and and press
CONTROL
1 2
008493

to confirm.)
For ETC, it’s possible to choose initiation or calibration, see Initiating
ETC, description page 28 and Calibrate ETC, description page 29).

8.5.1.1 Initiating ETC-Electronic Throttle

Control
Initiating ETC, description
page
–

Select Electronic throttle control, ETC, according to ETC, description

page 28.

ELECTRONIC THROTTLE Select initiation of ETC. To proceed, press function key .

CONTROL
008494

INITIATION

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 8 Control system – 8.5.1.2 Calibrate ETC-Electronic Throttle Control 29

INIT 1(4) Set the amount of output signal 0-100% (use and
4 ) to be sent
5

20 at 20% of pedal travel, (when pedal has been pressed down 20%). To
POWER OUTPUT 20

008489
AT 20% GAS proceed, press .
Lower value gives wider range for inching.
Set the amount of output signal 0-100% to be sent at 50% of pedal
INIT 2(4)
50 travel. This value can not be less than the previous setting at 20% in
POWER OUTPUT 50 menu 1(4).

008490
AT 50% GAS
A lower value gives a wider range for slow speed control, for example
when driving in hydrostatic mode on certain models.
Set the idling speed to be sent to the engine when the pedal is re-
INIT 3(4)
750 leased, 600-1000 rpm.
008491
MIN ENGINE RPM 750

Set the maximum speed to be sent to the engine when the pedal is ful-
INIT 4(4)
2200 ly depressed, 600 - 2400 rpm. This value can not be less than the pre-
008492

MAX ENGINE RPM 2200 vious setting in menu 3(4).

This is an example when:
“Power output at 20% gas” is set to 10%.
“Power output at 50% gas” is set to 30%.
This setting is suitable for hydrostatic transmission. It becomes easier
to drive very slowly, as well as exact positioning of machine.
In other cases, the following applies:
“Power output at 20% gas” is set to 20%.
“Power output at 50% gas” is set to 50%.

8.5.1.2 Calibrate ETC-Electronic Throttle

Control
Calibrate ETC, description
page
–

Select Electronic throttle control, ETC, according to ETC, description

page 28.
Select calibration of electronic throttle (ETC).
ELECTRONIC THROTTLE
CONTROL
008495

CALIBRATION

Calibration of accelerator pedal right front. Press down right pedal

CALIBR 1(8)
RIGHT FRONT 4417 completely and then press function key .
PEDAL TO 4417
008472

LOWER POSITION (mV)

Calibration of accelerator pedal right front. Release right pedal com-

CALIBR 2(8)
RIGHT FRONT 544 pletely and then press .
PEDAL TO 544
008473

UPPER POSITION (mV)

Display shown if hydrostatic transmission or inching is present in the

CALIBR 3(8)
LEFT FRONT 4403 machine.
PEDAL TO 4403
008474

Calibration of accelerator pedal left front. Press down left pedal fully
LOWER POSITION (mV)
and confirm with .

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30 8 Control system – 8.5.2 Automatic shifting

Display shown if hydrostatic transmission or inching is present in the

CALIBR 4(8)
LEFT FRONT 532 machine.
PEDAL TO 532

008475
Calibration of accelerator pedal left front. Release left pedal complete-
UPPER POSITION (mV)
ly and confirm with .
Calibration of accelerator pedal right rear. Press down right pedal
CALIBR 5(8)
RIGHT REAR 4406 completely and then press function key .
PEDAL TO 4406

008476
LOWER POSITION (mV) Display shown if the machine is equipped with a rotating or reversible
driver’s seat.
Calibration of accelerator pedal right rear. Release right pedal com-
CALIBR 6(8)
RIGHT REAR 549 pletely and then press .
PEDAL TO 549
008477

UPPER POSITION (mV) Display shown if the machine is equipped with a rotating or reversible
driver’s seat.
Calibration of accelerator pedal left rear. Press down left pedal fully
CALIBR 7(8)
LEFT REAR 4403 and confirm with .
PEDAL TO 4403
008478

LOWER POSITION (mV) Display shown if the machine is equipped with hydrostatic transmis-
sion or inching and a rotating seat.
Calibration of accelerator pedal left rear. Release left pedal completely
CALIBR 8(8)
LEFT REAR 532 and confirm with .
PEDAL TO 532
008479

UPPER POSITION (mV) Display shown if the machine is equipped with hydrostatic transmis-
sion or inching and a rotating seat.

8.5.2 Automatic shifting

Automatic shifting, description
page
–

Relevant gearbox functionality can be adjusted.

Initiation settings below is general to all gearbox models and can be
different depending on order, so called dynamic menus.

Go to the Setup menus by pressing function key in this menu.

000056

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Automatic Gear Shift.

AUTOMATIC GEAR SHIFT (Scroll to the desired menu with function keys 1 and 2 and press
ECU793 to confirm.)
008547

For automatic shift, it’s possible to choose initiation or calibration, see

Automatic shifting, description page 30.

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 8 Control system – 8.5.2.1 Initiating Automatic gear shift (ECU793) 31

8.5.2.1 Initiating Automatic gear shift

(ECU793)
Initiating Automatic gear shift, description
page
–

Select automatic gear shifting according to Automatic shifting, descrip-

tion page 30.
Enter initiation of automatic gearshift ECU793.
AUTOMATIC
GEAR SHIFT ECU793 This display and the following shows only if A_GEAR_SHIFT_793 is
INITIATION selected.

008548
INIT 1(3) Only shown if automatic gear shift is present on the machine.
ND
START IN 2 1 Start in 2nd gear means that the gearbox always start in second gear
GEAR 0
008549
ST ND and shifting is done between 2 and the highest available gear depend-
0=1 GEAR 1=2 GEAR
ing on model. Value 0 = start in 1st gear, value 1 = start in 2nd gear.

INIT 2(3) Only shown if automatic gear shift is present on the machine.
AUTOMATIC #### This parameter is used when selecting manual shifting. Value 0 = au-
GEARSHIFT OFF $$$$
008550

tomatic shift, value1 = manual shifting.

0=AUTO 1=MANUAL

Only shown when automatic gear shift and NOT inching is present in
INIT 3(3)
DECLUTCH #### the machine.
(CCO) OFF $$$$
008551

This parameter can be used to disable the declutch functionality that

0=ON 1=OFF
disengage the gearbox into neutral when brake pedal is pressed.
Value 0 = declutch active, value 1 = declutch disabled.

8.5.2.2 Calibrate Automatic gear shift,

description
Calibrate Automatic gear shift (transmission alternative
page
–

Dana), description

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

1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed.
2 Select automatic gear shifting according to Automatic shifting,
description page 30.
3 Select CALIBRATION by scrolling with the arrow keys (1 and 2)
AUTOMATIC 2(2) and confirm with Enter.
GEAR SHIFT ECU793
CALIBRATION
007742

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32 8 Control system – 8.5.2.2 Calibrate Automatic gear shift, description

4 Select “hEAt” by scrolling with the arrow keys (1 and 2) and con-
ECU793 D M firm with Enter.
E

007745
F S

5 Raise the temperature in the transmission by:

ECU793 D M A. Apply the parking brake so that the machine is stationary.
E
B. Select travel direction forward or backward and apply half to

007744
F S
maximum acceleration for 20 seconds.
C. Engage neutral position and apply half throttle for 10 sec-
onds, run the engine at idling speed.
D. Repeat steps B and C until the oil temperature is over 60 °C
or max 90 °C. The temperature display starts to flash when
calibration of the clutches can start.
6 Check that the gear control is in neutral position.
7 Select “trAn” by scrolling with the arrow keys (1 and 2) and con-
ECU793 D M firm with Enter.
E 8 Start calibration by selecting travel direction forward.
007745

F S

9 The current temperature is displayed if it is lower than 60°C. If

ECU793 D M not, “Go F” is displayed. If all conditions to start calibration are
E met, the calibration process starts.
007743

F S The transmission will activate different gears during calibration.

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

IMPORTANT
The transmission calibration process can be inter-
rupted at all times by moving the shift lever into the
reverse position.

10 Calibration starts (takes approx. 15 minutes).

ECU793 D M During calibration, “c1.n1”, “c1.n2”, “c2.n1”, “c2.n2” etc. are dis-
E played. This means clutch 1 and mode 1-2, clutch 2 and mode 1-
007747

F S 2 etc.
11 Depending on the actual calibrating mode, a different engine
speed may be required.
– Whenever the actual engine speed is too low following dis-
ECU793 D M play is shown:
E
007748

F S

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 8 Control system – 8.5.2.2 Calibrate Automatic gear shift, description 33

– When the actual engine speed is too high, the display looks
ECU793 D M as follows:
E

007749
F S

12 Change the throttle pedal position until the display looks like left.
ECU793 D M After the engine has been within limits for about three seconds,
E the calibration process proceeds.

007750
F S
After successful completion of the calibration process, the
calibration results are memorised in Flash memory.
13 After calibrating, donE is shown in the display.
ECU793 D M When one or more errors were encountered during calibration
E the display shows vertical lines to indicate the calibration result of
007751

F S each clutch (the first line corresponds to clutch1, the second line
to clutch2,…). A blinking line indicates the calibration of the cor-
responding clutch was no successful.
14 Turn off the ignition to store the values.
For further information see section 2 Transmission, group 2.8.11 Cal-
ibration.

Calibrate Automatic gear shift (transmission alternative

page
–

ZF), description

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

1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed.
2 Select automatic gear shifting according to Automatic shifting,
description page 30.
3 Select CALIBRATION by scrolling with the arrow keys (1 and 2)
AUTOMATIC 2(2) and confirm with Enter.
GEAR SHIFT ECU793
CALIBRATION
007742

4 Only shown when the engine is running.

CALIBRATION 1(2)
The signals for the parking brake and clutch disengagement have
GEARBOX HEAT MODE been temporarily disconnected to make it possible to run “Heat
009098

ACTIVATE P-BRAKE! Mode”. The highest possible gear is always selected.

5 “Heat mode” is a function for heating the transmission with the

CALIBRATION
transmission stationary, by using the parking brake to brake the
machine and let the torque converter heat the transmission oil.
FWD<->NTRL 15S CYCLE!
SELECTED GEAR F3
009541

TEMPERATURE 70”C

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

34 8 Control system – 8.5.2.2 Calibrate Automatic gear shift, description

NOTE
Stall the transmission for 15 sec., then select neutral to flush
the oil round and cool it for 10 sec. Repeat the procedure un-
til the desired oil temperature (70º C) has been reached.
When the transmission has reached the desired temperature, the
temperature value in the display will flash.
6 Only shown when the engine is running. Press “Enter” to come to
CALIBRATION 2(2)
the next menu.
AUTOMATIC CLUTCH
FILLING PARAMETER
009100
ADJUSTMENTS (AEB)

7 The following requirements must be complied with, to start cali-

CALIBRATION
bration. Transmission in neutral and parking brake applied.
>SELECT NEUTRAL
Check that all requirements are complied with and that the oil
>P-BRAKE ACTIVE
009101

>TEMP >70grC temperature is 70° before you go on to the next menu by pressing
Enter.
8 When the TCU has started calibration, the display shows infor-
CALIBRATION
mation in plain language about the calibration procedure. Any
STATUS
fault messages are also displayed.
009103

K1 ADJUST! 9 During calibration, engine speed is automatically regulated to the

default value which suits each transmission.
After calibration is completed, the display will show the text: “AD-
JUSTMENT FINISHED SWITCH OFF IGNITION FOR 5 SEC-
ONDS!”, for saving the new parameters.
10 This is only shown when the engine is switched off and inching is
CALIBRATION 2(2)
installed. This is an optional feature.
009104

INCH PEDAL The requirement for seeing “CALIBRATION INCH PEDAL” is that
the engine is already switched off. This will not be displayed at all
otherwise.
--> Engine switched off = INCH PEDAL CALIBRATION
Engine running = AEB CLUTCH CALIBRATION
11 When the TCU has started calibration, the display shows infor-
CALIBRATION
mation in plain language about the calibration procedure. Any
STATUS
fault messages are also displayed.
009105

PRESS PEDAL SLOW! 12 Depress the pedal slowly and keep it depressed until the text
shown on the display changes to “Release pedal slow!”. Release
the pedal slowly.
After successful calibration, switch off ignition for 5 s for saving
the new parameters.

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

 8 Control system – 8.5.4 Feedback lever steering 35

8.5.4 Feedback lever steering

Feedback lever steering, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056
To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Lever steering.

(Scroll to the desired menu with function keys and and press
LEVER STEERING 1 2

to confirm.)
For Lever steering, it’s possible to choose initiation or calibration, see
000741

Initiating Feedback lever steering, description page 35 and Calibrating

Feedback lever steering, description page 39).

8.5.4.1 Initiating Feedback lever steering

Initiating Feedback lever steering, description
page
–

Select Lever steering according to Feedback lever steering, descrip-

tion page 35.
Select initiation for Lever steering.
LEVER STEERING

INITIATION
000742

Indicates steering lever’s linearity.

INIT 1(12) 0 = the wheel angle is equal in relation to the lever deflection during
CHARACTERISTIC 3
the entire lever movement.
STEERING LEVER 3
0-10, 0=LIN 10 = the wheel angle is small at the beginning of the lever movement
004754

and large at the end.

Recommended value: 3
Setting of speed at reference point 1. Affects steering characteristics.
INIT 2(12) Recommended value: 5 km/h or acc. to operator’s wishes.
SPEED AT 5.0
BREAK POINT 1 5.0 For adjusting, see Adjusting lever steering page 37.
008565

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36 8 Control system – 8.5.4.1 Initiating Feedback lever steering

Setting of speed at reference point 2. Affects steering characteristics.

INIT 3(12) Recommended value: 10 km/h or acc. to operator’s wishes.
SPEED AT 10.0
BREAK POINT 2 10.0 For adjusting, see Adjusting lever steering page 37.

008566
Setting of speed at reference point 3. Affects steering characteristics.
INIT 4(12) Recommended value: 15 km/h or acc. to operator’s wishes.
SPEED AT 15.0
BREAK POINT 3 15.0 For adjusting, see Adjusting lever steering page 37.

008567

Percent of max. steering capacity (% steering value) at reference point

INIT 5(12) 2. Reduces the steering lever’s influence when speed increases.
80 For adjusting, see Adjusting lever steering page 37.
% STEERVALUE 80
AT BREAKPOINT 2
008617

Percent of max. steering capacity (% steering value) at reference point

INIT 6(12) 3. Reduces the steering lever’s influence when speed increases.
60 For adjusting, see Adjusting lever steering page 37.
% STEERVALUE 60
AT BREAKPOINT 3
008618

Sensitivity of steering lever’s change.

INIT 7(12) Low value gives slow change.
5
SENSITIVITY 5 High value gives fast change.
DEFAULT VALUE 1-9 Recommended value: 5, if 0 = the latest adjusted value is memorised
004753

and used when starting the machine.

This display is shown if feedback is included.

INIT 8(12) Indicates the wheel angle that is accepted when triggering begins.
10 Normally not adjusted.
DEAD ZONE 10
WHEEL ANGLE Recommended value: 10
000750

Start current for when the valve starts to move (where the valve pre-
cisely starts to open and gives a small flow to the steering cylinder).
INIT 9(12)
330 For adjusting, see Adjusting lever steering page 37
MIN CURRENT 330
STEERING RIGHT (mA)
008619

Current for fully open valve.

INIT 10(12) For adjusting, see Adjusting lever steering page 37.
510
MAX CURRENT 510
STEERING RIGHT (mA)
000752

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 8 Control system – 8.5.4.1 Initiating Feedback lever steering 37

Same setting as in menu 9 but for left steering angle.

INIT 11(12) For adjusting, see Adjusting lever steering page 37.
330
MIN CURRENT 330
STEERING LEFT (mA)

008620
Same setting as in menu 10 but for left steering angle.
INIT 12(12) For adjusting, see Adjusting lever steering page 37.
510
MAX CURRENT 510
STEERING LEFT (mA)

000754

Adjusting lever steering

page
–

For adjusting, see

1. Adjusting currents for lever steering/mini-wheel
2. Possible setting of dead zone (only for feedback lever steering)
3. Setting of sensitivity
4. Setting of speed dependence
5. Setting of characteristics (Characteristic steer lever)
6. Test-run

Adjusting currents for lever steering/mini-wheel

To find the best value for start currents:
• Set MIN CURRENT STEERING LEFT and MAX CURRENT
STEERING LEFT to the same value. Start with 300 mA. Start cur-
rent and final current are set to the same value to know exactly
what current the steering valve receives.
• Steer to the left (with lever/mini-wheel). The wheels should move
slowly. If the wheels don’t move, increase the current values a
couple of steps and try again. When this is done, one has to stand
on the footstep to assess how the wheels move. When the correct
value has been found, the wheels move slowly.
• Repeat for control current right.
• Note that steering speed should be the same in both directions.
• The final value is used for MIN CURRENT STEERING LEFT and
RIGHT.
To find the best value for final currents:
• Set MAX CURRENT STEERING LEFT to 510 mA and MAX CUR-
RENT STEERING RIGHT to 510 mA.
• Check that the machine has the same steering speed in both di-
rections when the steering lever is deflected completely (or mini-
wheels is turned fast, approx. one steering wheel turn per sec-
ond). When this is done, one has to stand on the footstep to as-
sess how the wheels move. Steering speed may vary slightly
depending on if the engine is running at idle or at a higher rpm.

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38 8 Control system – 8.5.4.1 Initiating Feedback lever steering

• Test-run the machine and try to assess if the steering capacity is

sufficient at low speeds, can the machine be turned fast enough?
If not, increase final currents slightly and try again.

Possible setting of dead zone (only for feedback lever

steering)
If the steering axle oscillates (difficult remaining stationary) it may be
due to the dead zone being set to low. Increase it slightly.

Setting of sensitivity
If fast steering is desired with high sensitivity, set “SENSITIVITY” to
high. Slow steering is given with a low value.
A new inexperienced operator often wants slow, forgiving steering.
An experienced operator expects fast reactions from lever/steering
wheel to the steering axle.

Setting of characteristics (Characteristic steer lever)

Indicates steering lever’s characteristics.
Output signal
0= steering angle is equal in relation to the lever deflection during the
entire steering movement (linear).
10= steering angle is small at beginning of the lever movement and
greater at the end.
004196

Lever deflection

Setting of speed dependence

The diagram explains how speed dependence can be adjusted using
Break point 3
Break point 1 Break point 2
the break points.
For break point 1, indicated at what speed it applies (for example, 5
Speed dependence
km/h), but steering capacity is always 100% For break point 2, enter
120
% of max steering capacity

speed (for example, 10 km/h) and steering capacity (for example,

100
90%). For break point 3, enter speed (for example, 15 km/h) and steer-
80
ing capacity (for example, 80%).
60

40 If one wants steering to be even more “careful” at high speed, the val-
20 ue shall be changed as follows:
0
0 5 10 15 20 25 30 35
For break point 1, enter speed 5 km/h For break point 2, enter speed
10 km/h and steering capacity 75%. For break point 3, enter speed 15
004197

Speed
km/h and steering capacity 50%.
If one wants steering to be completely without speed dependence, the
value shall be changed as follows:
For break point 1, enter speed 5 km/h For break point 2, enter speed
10 km/h and steering capacity (100%). For break point 3, enter speed
15 km/h and steering capacity (100%).

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

 8 Control system – 8.5.4.2 Calibrating Feedback lever steering 39

The speed limits and break points may be adjusted according to cus-
tomers’ wishes. However, it’s important to not “stretch the limits” too
far. Change and test.

Test-run
Don’t forget to test-run the machine in different situations. Setting of
the start currents is very sensitive. The machine must steer even when
the steering wheel is turned slowly, otherwise it’s impossible to travel
straight at full speed. The result may be that regardless of how much
one steers, at first nothing happens, then the machine turns sharply.
Then the cause is that the start currents are set too low, see above.
If start currents are set too high, the machine’s steering feels very un-
stable and erratic at high speeds. It’s impossible to steer carefully as
the smallest turn of the steering wheel results in a large wheel angle.

8.5.4.2 Calibrating Feedback lever steering

Calibrating Feedback lever steering, description
page
–

Select Lever steering according to Feedback lever steering, descrip-

tion page 35.
Select calibration for lever steering.
LEVER STEERING

CALIBRATION
000755

Don’t touch the steering lever when calibrating the middle position.
CALIBR 1(6) Display shows steering lever’s middle position. Press to save this
STEERING LEVER 2442 position as “middle position”.
TO CENTRE 2442
POSITION (mV)
000756

Move the lever to the far left. Display shows steering lever’s position.
CALIBR 2(6) Press to save this position.
STEERING LEVER 4526
TO LEFT 4526
POSITION (mV)
000757

Move the lever to the far right. Display shows steering lever’s position.
CALIBR 3(6) Press to save this position.
STEERING LEVER 435
TO RIGHT 435
POSITION (mV)
000758

The following displays are shown if feedback is included.

CALIBR 4(6) Adjust the wheels until they are parallel with the machine. (To obtain
SET WHEELS IN 2393 best result, run the machine straight with the normal steering wheel).
CENTRE 2393
POSITION (mV) Display shows wheel’s position. Press to save this value.
000759

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40 8 Control system – 8.5.5 NON feedback lever steering

Turn the steering wheel to max. left. Display shows wheel’s position.
CALIBR 5(6) Press to save this value.
TURN STEERING 538
WHEEL TO MAX 538
LEFT POSITION (mV)

000760
Turn the steering wheel to max. right. Display shows wheel’s position.
CALIBR 6(6) Press to save this value.
TURN STEERING 4411
WHEEL TO MAX 4411
RIGHT POSITION (mV)
000761

8.5.5 NON feedback lever steering

NON feedback lever steering, description
page
–

See Feedback lever steering, description page 35.

8.5.5.1 Initiating NON feedback lever steering

Initiating NON feedback lever steering, description
page
–

See Initiating Feedback lever steering, description page 35.

8.5.5.2 Calibrating NON feedback lever

steering
Calibrating NON feedback lever steering, description
page
–

See Calibrating Feedback lever steering, description page 39 menu 1-

3.

8.5.6 Mini-wheel
Mini-wheel, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Mini steering.

(Scroll to the desired menu with function keys and and press
MINI STEERING 1 2

to confirm.)
For Mini-wheel (Mini steering), it’s only possible to select initiation, see
000769

Initiating Mini-wheel, description page 41).

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 8 Control system – 8.5.6.1 Initiating Mini-wheel 41

8.5.6.1 Initiating Mini-wheel

Initiating Mini-wheel, description
page
–

Select Mini steering according to Mini-wheel, description page 40.

Setting of speed at reference point 1 (BP1). Affects steering charac-
INIT 1(10) teristics.
SPEED AT 5 Recommended value: 5km/h.
BREAK POINT 1 5
For adjusting, see Adjusting lever steering page 37.

000770
Setting of speed at reference point 2 (BP2). Affects steering charac-
INIT 2(10) teristics.
SPEED AT 10 Recommended value: 10km/h.
BREAK POINT 2 10
For adjusting, see Adjusting lever steering page 37.
000771

Setting of speed at reference point 3 (BP3). Affects steering charac-

INIT 3(10) teristics.
SPEED AT 15 Recommended value: 15km/h.
BREAK POINT 3 15
For adjusting, see Adjusting lever steering page 37.
000772

Percent of max. steering capacity (% steering value) at reference point

INIT 4(10) 2. Reduces the mini-wheel’s influence when speed increases.
80 Recommended value: 80%.
% STEERVALUE 80
AT BREAKPOINT 2 For adjusting, see Adjusting lever steering page 37.
008621

Percent of max. steering capacity (% steering value) at reference point

INIT 5(10) 3. Reduces the mini-wheel’s influence when speed increases.
60 Recommended value: 60%.
% STEERVALUE 60
AT BREAKPOINT 3 For adjusting, see Adjusting lever steering page 37.
008622

Sensitivity of mini-wheel’s change.

INIT 6(10) Low value gives many steering wheel turns from lock-to-lock.
5
SENSITIVITY 5 High value gives few steering wheel turns from lock-to-lock.
DEFAULT VALUE 1-9 Recommended value: 5, if 0 = the latest adjusted value is memorised
004545

and used when starting the machine.

Start current for when the valve starts to move (where the valve pre-
INIT 7(10) cisely starts to open and gives a small flow to the steering cylinder).
300 For adjusting, see Adjusting lever steering page 37.
MIN CURRENT 300
STEERING RIGHT (mA)
004532

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42 8 Control system – 8.5.7 Electro-hydraulic servo

Current for fully open valve.

INIT 8(10) For adjusting, see Adjusting lever steering page 37.
510
MAX CURRENT 510
STEERING RIGHT (mA)

000777
Same setting as in menu 7 but for left steering angle.
INIT 9(10) For adjusting, see Adjusting lever steering page 37.
300
MIN CURRENT 300
STEERING LEFT (mA)
004533

Same setting as in menu 8 but for left steering angle.

INIT 10(10) For adjusting, see Adjusting lever steering page 37.
510
MAX CURRENT 510
STEERING LEFT (mA)
000779

Adjusting mini-wheel
page
–

See Adjusting lever steering page 37.

8.5.7 Electro-hydraulic servo

Electro-hydraulic servo, description
page
–

Each function can be set individually and must be calibrated. Thus, 10

solenoid valves have to be calibrated and initiated for 5 hydraulic func-
tions.
The first step for activating the electric servo is a basic setting called
Initiation. That’s where the dead zone is indicated for the levers, as
well as min. and max. currents for the solenoid valves.
The procedure for setting the min. current for the solenoid valves is to
set both min. and max. currents to the same value, for example
260mA, and then increase successively until a movement is obtained
for each hydraulic function. The value one has stopped at shall be the
value for the min. current.
Max. current should be the one specified as max. by the valve manu-
facturer. For Parker L90, the range is 260 – 510 mA. In certain cases,
a lower max. current may be set for better adaptation of hydraulic
movement speed and synchronisation with engine performance and
capacity of the hydraulic pumps.

Go to the Setup menus by pressing function key in this menu.

000056

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 8 Control system – 8.5.7.1 Initiating Electro-hydraulic servo 43

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5

000060
Select Electro-hydraulic servo.

(Scroll to the desired menu with function keys and and press
ELHYDRAULIC SERVO 1 2

to confirm.)
For Electro-hydraulic servo, it’s possible to choose initiation or calibra-

000780
tion, see Initiating Electro-hydraulic servo, description page 43 and
Calibrating Electro-hydraulic servo, description page 46).

8.5.7.1 Initiating Electro-hydraulic servo

Initiating Electro-hydraulic servo, description
page
–

Select electric servo according to Electro-hydraulic servo, description

page 42.
Select initiation of electric servo.
ELHYDRAULIC SERVO

INITIATION
000781

Indicate how much of the steering lever’s movement around the mid-
INIT 1(25) dle position should be interpreted as middle position (dead zone). The
30 range is 30 – 1000 of the total lever movement’s +/-1000. The value
DEAD ZONE 30 should be set as small as possible. Rec. value is 30. The dead zone
LEVERS 30-1000 range is necessary so that the hydraulic movements don’t vibrate
008569

when operating the machine, especially on rough surfaces.

Start value, min. current, for lowering movement’s control valve. This
INIT 2(25) display is shown if one or more hydraulic functions have been select-
FUNCTION 1A 260 ed.
(LOWER) 260
MIN CURRENT (mA)
004547

Stop value, max. current, for lowering movement’s control valve. This
INIT 3(25) display is shown if one or more hydraulic functions have been select-
FUNCTION 1A 510 ed.
(LOWER) 510
MAX CURRENT (mA)
004548

Start value, min. current, for lifting movement’s control valve. This dis-
INIT 4(25) play is shown if one or more hydraulic functions have been selected.
FUNCTION 1B 260
(LIFT) 260
MIN CURRENT (mA)
004549

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44 8 Control system – 8.5.7.1 Initiating Electro-hydraulic servo

Stop value, max. current, for lifting movement’s control valve. This dis-
INIT 5(25) play is shown if one or more hydraulic functions have been selected.
FUNCTION 1B 510
(LIFT) 510
MAX CURRENT (mA)

004550
Start value, min. current, for tilt out movement’s control valve. This dis-
INIT 6(25) play is shown if two or more hydraulic functions have been selected.
FUNCTION 2A 260
(TILT OUT) 260
MIN CURRENT (mA)
004551

Stop value, max. current, for tilt out movement’s control valve. This
INIT 7(25) display is shown if two or more hydraulic functions have been select-
FUNCTION 2A 510 ed.
(TILT OUT) 510
MAX CURRENT (mA)
004552

Start value, min. current, for tilt in movement’s control valve. This dis-
play is shown if two or more hydraulic functions have been selected.
INIT 8(25)
FUNCTION 2B 260
(TILT IN) 260
MIN CURRENT (mA)
004553

Stop value, max. current, for tilt in movement’s control valve. This dis-
INIT 9(25) play is shown if two or more hydraulic functions have been selected.
FUNCTION 2B 510
(TILT IN) 510
MAX CURRENT (mA)
004554

Start value, min. current, for left side shift movement’s control valve.
INIT 10(25) This display is shown if three or more hydraulic functions have been
FUNCTION 3A 260 selected.
(SHIFT LEFT) 260
MIN CURRENT (mA)
008573

Stop value, max. current, for left side shift movement’s control valve.
This display is shown if three or more hydraulic functions have been
INIT 11(25)
FUNCTION 3A 510 selected.
(SHIFT LEFT) 510
MAX CURRENT (mA)
004556

Start value, min. current, for right side shift movement’s control valve.
This display is shown if three or more hydraulic functions have been
INIT 12(25)
FUNCTION 3B 260 selected.
(SHIFT RIGHT) 260
MIN CURRENT (mA)
004557

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 8 Control system – 8.5.7.1 Initiating Electro-hydraulic servo 45

Stop value, max. current, for right side shift movement’s control valve.
This display is shown if three or more hydraulic functions have been
INIT 13(25)
FUNCTION 3B 510 selected.
(SHIFT RIGHT) 510
MAX CURRENT (mA)

004558
Start value, min. current, for positioning outward movement’s control
valve. This display is shown if four or more hydraulic functions have
INIT 14(25)
FUNCTION 4A 260 been selected.
(SPREAD OUT) 260
MIN CURRENT (mA)

004559
Stop value, max. current, for positioning outward movement’s control
valve. This display is shown if four or more hydraulic functions have
INIT 15(25)
FUNCTION 4A 510 been selected.
(SPREAD OUT) 510
MAX CURRENT (mA)
004560

Start value, min. current, for positioning inward movement’s control

valve. This display is shown if four or more hydraulic functions have
INIT 16(25)
FUNCTION 4B 260 been selected.
(SPREAD IN) 260
MIN CURRENT (mA)
004561

Stop value, max. current, for positioning inward movement’s control

INIT 17(25) valve. This display is shown if four or more hydraulic functions have
FUNCTION 4B 510 been selected.
(SPREAD IN) 510
MAX CURRENT (mA)
008570

Start value, min. current, for upward levelling movement’s control

valve. This display is shown if five or more hydraulic functions have
INIT 18(25)
FUNCTION 5A 260 been selected.
(EXTRA) 260
MIN CURRENT (mA)
004563

Stop value, max. current, for upward levelling movement’s control

valve. This display is shown if five or more hydraulic functions have
INIT 19(25)
FUNCTION 5A 510 been selected.
(EXTRA) 510
MAX CURRENT (mA)
004564

Start value, min. current, for downward levelling movement’s control

valve. This display is shown if five or more hydraulic functions have
INIT 20(25)
FUNCTION 5B 260 been selected.
(EXTRA) 260
MIN CURRENT (mA)
004565

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46 8 Control system – 8.5.7.2 Calibrating Electro-hydraulic servo

Stop value, max. current, for downward levelling movement’s control

valve. This display is shown if five or more hydraulic functions have
INIT 21(25)
FUNCTION 5B 510 been selected.
(EXTRA) 510
MAX CURRENT (mA)

004566
8.5.7.2 Calibrating Electro-hydraulic servo
Calibrating Electro-hydraulic servo, description
page
–

This is the second step after basic setting in the initiation menus. Cal-
ibration has to be performed to adapt the lever’s output signal and so
that maximum range from the lever can be used by KCS. This must
also be done after replacing a lever.
Select electric servo according to Electro-hydraulic servo, description
page 42.
Select calibration for electro-hydraulic servo.

ELHYDRAULIC SERVO

CALIBRATION
000679

Calibration of voltage for lowering function. When the lever is in max.

CALIBR 1(10) position for lower, press function key .
F1A (LOWER) 867
LEVER TO MAX 867
POSITION (mV)
004757

Calibration of voltage for lifting function. When the lever is in max. po-
CALIBR 2(10) sition for lift, press function key .
F1B (LIFT) 8775
LEVER TO MAX 8775
POSITION (mV)
004758

Calibration of voltage for tilt out function. When the lever is in max. po-
CALIBR 3(10) sition for tilt out, press function key .
F2A (TILT OUT) 867
LEVER TO MAX 867
POSITION (mV)
004759

Calibration of voltage for tilt in function. When the lever is in max. po-
CALIBR 4(10) sition for tilt in, press function key .
F2B (TILT IN) 8775
LEVER TO MAX 8775
POSITION (mV)
004760

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 8 Control system – 8.5.7.2 Calibrating Electro-hydraulic servo 47

Calibration of voltage for side shift left function. When the lever is in
CALIBR 5(10) max. position for left side shift, press function key .
F3A (SHIFT 867
LEFT) LEVER TO 867
MAX POSITION (mV)

004761
Calibration of voltage for side shift right function. When the lever is in
CALIBR 6(10) max. position for right side shift, press function key .
F3B (SHIFT 8775
RIGHT)LEVER TO 8775
MAX POSITION (mV)

004762
Calibration of voltage for fork positioning out function. When the lever
CALIBR 7(10) is in max. position for positioning outward, press function key .
F4A (SPREAD 867
OUT) LEVER TO 867
MAX POSITION (mV)
004763

Calibration of voltage for fork positioning in function. When the lever is

CALIBR 8(10) in max. position for positioning inward, press function key .
F4B (SPREAD 8775
IN) LEVER TO 8775
MAX POSITION (mV)
004764

Calibration of voltage for levelling up function. If 4 hydraulic functions

have been selected in setup, this display is not shown. When the lever
CALIBR 9(10)
F5A (EXTRA) 867 is in max. position for upward levelling, press function key .
LEVER TO 867
MAX POSITION (mV)
004765

Calibration of voltage for levelling down function. If 4 hydraulic func-

tions have been selected in setup, this display is not shown. When the
CALIBR 10(10)
F5B (EXTRA) 8775 lever is in max. position for downward levelling, press function key .
LEVER TO 8775
MAX POSITION (mV)
004766

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48 8 Control system – 8.5.8 Scale

8.5.8 Scale
Scale, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056
To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Scale.

SCALE (Scroll to the desired menu with function keys 1 and 2 and press
to confirm.)
For Scale, it’s only possible to select calibration, Calibrating scale, de-
000803

scription page 48).

8.5.8.1 Calibrating Scale

Calibrating scale, description
page
–

See Maintenance manual for DCE 90–80, DCE 70-32E3–70-35E4.

8.5.9 Monitoring
Monitoring, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the settings can be accessed to per-
form settings.
1 23
4 5
000060

Select Monitoring.

MONITORING (Scroll to the desired menu with function keys 1 and 2 and press
to confirm.)
For Monitoring, it’s only possible to select initiation, see Initiating Mon-
000806

itoring, description page 49).

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

 8 Control system – 8.5.9.1 Initiating Monitoring 49

8.5.9.1 Initiating Monitoring

Initiating Monitoring, description
page
–

Select Monitoring according to Monitoring, description page 48.

Menu for setting service interval. Access directly via the service code.
INIT 1(1)
50h Enter new interval with 4 and 5 and press function key to con-
SERVICE 50h firm. On delivery from the factory, this should be set to 50 h.
INTERVAL 0-1000

008568
Resetting the service interval
–

NOTE
This menu can only be accessed by entering the special code
500h TO NEXT SERVICE (authorization required) instead of the service code.
PRESS ENTER TO
CONFIRM! Menu for resetting service time (time to next service).
000808

Press function key to confirm.

8.5.10 Pre-selected lifting height

Pre-selected lifting height, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Preselect lift height.

PRESELECT LIFTHEIGHT (Scroll to the desired menu with function keys 1 and 2 and press
to confirm.)
For Pre-selected lifting height, it’s only possible to select calibration,
001233

see Calibrating Pre-selected lifting height, description page 49).

8.5.10.1 Calibrating Pre-selected lifting height

Calibrating Pre-selected lifting height, description
page
–

Select Preselect lift height according to Pre-selected lifting height, de-

scription page 49.

CALIBR 1(2) Lower the carriage to the lowest position and adjust with key 4 and
640 0 mm 5 to the measured lift height in question.
640 0 mm
008574

LOWEST POSITION Press function key to confirm lowest position.

Min. lift height (in millimetres) can be read off at the bottom right.

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

50 8 Control system – 8.5.11 Tilt control

Min. lift height (in millivolt) can be read off at the bottom left.

CALIBR 2(2) Lift the carriage to the highest position and adjust with key 4 and 5

8092 5500 mm to the measured lift height in question.

8092 5500 mm

008575
HIGHEST POSITION Press function key to confirm highest position.
Max. lift height (in millimetres) can be read off at the bottom right.
Max. lift height (in millivolt) can be read off at the bottom left.

8.5.11 Tilt control

Tilt control, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Tilt control.

(Scroll to the desired menu with function keys and and press
TILT CONTROL 1 2

to confirm.)
For Tilt control, it’s only possible to select calibration, see Calibrating
001236

Tilt control, description page 50).

8.5.11.1 Calibrating Tilt control

Calibrating Tilt control, description
page
–

Select Tilt control according to Tilt control, description page 50.

Move the mast to vertical position without load.
CALIBR 1(2)
Press function key to confirm vertical position.
VERTICAL 1560 Angle without load (in millivolt) can be read off at the bottom.
POSITION 1560
001237

WITHOUT LOAD (mV)

Move the mast to vertical position with load. It is a good idea to select
CALIBR 2(2) a load which is frequently used for work with the tilt control.

VERTICAL 2387 Press function key to confirm vertical position.

POSITION 2387 Angle with load (in millivolt) can be read off at the bottom.
001238

WITH LOAD (mV)

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

 8 Control system – 8.5.12 OptimumLift 51

8.5.12 OptimumLift
OptimumLift, description
page
–

As with all variable pumps, it is essential to ensure that it is filled with

oil before and after the engine is started, so that the rotating compo-
nents are lubricated. If this is missed, and the pump is run dry for only
a few minutes, this can lead to pump failure. One tip is to use the di-
agnostic function in KCS and “Control Outputs” to force the variable
pump when the engine is first started, and ensure that the pump re-
ceives oil.
Force the pump by going into “Control outputs”, set a voltage on K2:12
and allocate 600 mA to K2:28 to set the pump to maximum delivery.

NOTE
The fork trolley starts to move!
When the fork trolley starts to move, the pump has received enough
oil. Forcible operation of the pump can now be shut off. For more de-
tailed information, please refer to Diagnostics, description page 6.

Please refer to the information below, for setting the basic parameters.

Go to the Setup menus by pressing function key in this menu.

000056

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select OptimumLift.

OPTILIFT
OPTISPEED/REV (Scroll to the desired menu with function keys 1 and 2 and press
/SPEED/REV to confirm.)
014868

For OptimumLift, it’s possible to choose initiation or calibration, see

004986

OptimumLift, description page 51 and Initiating OptimumLift, descrip-

tion page 52).

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52 8 Control system – 8.5.12.1 Initiating OptimumLift

8.5.12.1 Initiating OptimumLift

Initiating OptimumLift, description
page
–

Select OptimumLift according to OptimumLift, description page 51.

Select initiation of OptimumLift.
OPTILIFT
OPTISPEED/REV
/SPEED/REV

014869
004534
INITIATION

Initiation of min. current to OptimumLift valve monitoring a variable

INIT 1(6) pump. Relevant value is 400 mA.
MIN CURRENT TO 400
OPTILIFT/SPEED
OPTISPEED/REV 400
/REV
VALVEVALVE (mA)
014870
004987

Initiation of max. current to OptimumLift valve monitoring a variable

INIT 2(6) pump. This value decides which speed the lift function gets. If Parker
MAX CURRENT TO 1750 DF161C direction valve with 42 W coil is used and maximum lift speed
OPTILIFT/SPEED 1750 is wanted, then the value is set to 1750 mA.
/REV VALVE (mA)
014871

Initiation of the min. load where OptimumLift or OptimumRev starts

INIT 3(6) steering down the variable pump towards min. current. Change with
MIN LOAD 500
and .
OPTILIFT/SPEED 500 4 5

/REV
014872

ACTUAL LOAD 1500

Initiation of the max. load where OptimumLift has steered down the
INIT 4(6)
variable pump to min. current. Change with and .
MAX LOAD 4500
4 5

OPTILIFT/SPEED 4500
/REV
014873

ACTUAL LOAD 1500

Initiation of the min. rpm when OptimumLift starts steering out the var-
INIT 5(6) iable pump. Relevant value is 900–1000 rpm.
MIN RPM 1000
OPTILIFT/SPEED
OPTISPEED/REV 1000
/REV
014874
004991

Initiation of the max. rpm when OptimumLift steers out the variable
INIT 6(6) pump max. or the work speed that limits OptimumRev at drive break.
MAX RPM 1500 Relevant value is 1500 rpm.
OPTILIFT/SPEED 1500
/REV
014875

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 8 Control system – 8.5.12.2 Calibrating OptimumLift 53

8.5.12.2 Calibrating OptimumLift

Calibrating OptimumLift, description
page
–

Select OptimumLift according to OptimumLift, description page 51.

Select calibration of OptimumLift.
OPTILIFT/DRIVE
OPTISPEED/REV
/SPEED/REV

014876
004535
CALIBRATION

Calibration of the pressure sensor signal from the lift lever (start move-
CALIBR 1(2) ment).
500 The starting value should be when the lifting cylinders have just started
LIFT LEVER IN 500 to move, with the Optipump disconnected.
START POSITION
002300

Not shown if an electro-hydraulic servo is installed.

Calibration of the pressure sensor signal from the lift lever (end move-
CALIBR 2(2) ment).
4500 The signal must not exceed 4.5 V. If it does so, the hydraulic pressure
LIFT LEVER IN 4500 can be set too high, above 40 bar.
MAX LIFT POSITION
002301

Not shown if electro-hydraulic servo is installed.

8.5.14 Clamp and lift function/lower and

open function
8.5.14.1 Initiating Clamp and lift function/lower
and open function
Initiating Clamp and lift function/lower and open function,
page
–

description
No extra setting is needed, apart from what is needed for the scale,
please refer to Scale, description page 48 and the automatic clamping
function, Automatic clamping function, description page 54.

8.5.14.2 Calibrating Clamp and lift function/

lower and open function
Calibrating Clamp and lift function/lower and open
page
–

function, description, description

No extra setting is needed, apart from what is needed for the scale,
please refer to Scale, description page 48 and the automatic clamping
function, Automatic clamping function, description page 54.

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

54 8 Control system – 8.5.15 Automatic clamping function

8.5.15 Automatic clamping function

Automatic clamping function, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056
To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5
000060

Select Clamp unit.

(Scroll to the desired menu with function keys and and press
CLAMP UNIT 1 2

to confirm.)
For the Automatic clamping function, it is possible to choose initiation
004239

or calibration, see Initiating Automatic clamping function, description

page 54 and Calibrating Automatic clamping function, description
page 55).

8.5.15.1 Initiating Automatic clamping function

Initiating Automatic clamping function, description
page
–

Select Automatic clamping function according to Automatic clamping

function, description page 54.
Select initiation of Automatic clamping function.

CLAMP UNIT

INITIATION
004340

Select the pressure for position 1. Confirm with .

INIT 1(4)
CLAMP 70
PRESSURE 1 70
(50-180 bar)
008553

Select the pressure for position 2. Confirm with .

INIT 2(4)
CLAMP 90 Only displayed if the automatic clamping function with four positions is
PRESSURE 2 90 used.
(50-180 bar)
008554

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 8 Control system – 8.5.15.2 Calibrating Automatic clamping function 55

Select the pressure for position 3. Confirm with .

INIT 3(4)
CLAMP 110 Only displayed if the automatic clamping function with four positions is
PRESSURE 3 110 used.
(50-180 bar)

008555
Select the pressure for position 4. Confirm with .
INIT 4(4)
CLAMP 140 Only displayed if the automatic clamping function with four positions is
PRESSURE 4 140 used.
(50-180 bar)

008556

8.5.15.2 Calibrating Automatic clamping

function
Calibrating Automatic clamping function, description
page
–

Select Automatic clamping function according to Automatic clamping

function, description page 54.
Select calibration of Automatic clamping function.

CLAMP UNIT

CALIBRATION
004345

Close the automatic clamping unit completely. Open slightly, so that

CALIBR 1(4) the clamp is almost in the closed position, but has no pressure. Press
CLOSE THE CLAMP to start the automatic calibration.
WITHOUT PRESSURE.
PRESS ENTER FOR It is a good idea to do calibration with a roll. The clamping pressure will
008557

CALIBRATION! rise to 160 bar during calibration, which can damage the roll, so use
an already damaged roll.
The automatic clamping function is calibrated. The current on the “car-
CALIBR 2(4) tridge” is slowly increased. Current and pressure are registered.

CALIBRATING!
008558

Calibration completed. The values are stored in the ECU memory.

CALIBR 3(4)

CALIBRATION
COMPLETED!
008559

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56 8 Control system – 8.5.16 Protection against loose chain tension

Calibration failed. The values are not saved.

CALIBR 4(4) The reason for this is that the pressure was too high when calibration
started (p>40 bar), or that the pressure did not reach 160 bar during
CALIBRATION calibration.
FAILED!

008560
8.5.16 Protection against loose chain
tension
8.5.16.1 Initiating Protection against loose
chain tension
Initiating Protection against loose chain tension,
page
–

description

No extra setting is needed, apart from what is needed for the scale,
please refer to Scale, description page 48.

8.5.16.2 Calibrating Protection against loose

chain tension
Calibrating Protection against loose chain tension,
page
–

description

No extra setting is needed, apart from what is needed for the scale,
please refer to Calibrating scale, description page 48.

8.5.17 Protection against inadvertent

opening of the clamp
8.5.17.1 Initiating Protection against
inadvertent opening of the clamp
Initiating Protection against inadvertent opening of the
page
–

clamp, description

No extra setting is needed, apart from what is needed for the scale,
please refer to Scale, description page 48.

8.5.17.2 Calibrating Protection against

inadvertent opening of the clamp
Calibrating Protection against inadvertent opening of the
page
–

clamp, description

No extra setting is needed, apart from what is needed for the scale,
please refer to Calibrating scale, description page 48.

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

 8 Control system – 8.5.18 Automatic lowering stop 57

8.5.18 Automatic lowering stop

Automatic lowering stop, description
page
–

Can only be installed on vehicles equipped with paper handling equip-

ment
The vehicle is equipped with a sensor which “senses” when a roll is
lowered past the sensing range of the sensor (K1:41 switches to 24V).
Lowering is stopped if the roll is a pre-determined distance from the
ground and vehicle speed exceeds 0.5 km/h.
Lowering the last part of the distance is only permitted when the vehi-
cle speed is less than 0.5 km/h (stationary).

8.5.19 Driving interlock

Driving interlock, description
page
–

The function prevents driving faster than 3 km/h after the roll/bale has
been clamped but not lifted. The roll must first be lifted 100 mm, if lift-
height sensor is present, and the scales must indicate at least 10%
load before driving is permitted.
The function uses the scales and a distance sensor for lifting height if
present.

8.5.20 Speed limitation related to lift height

Speed limitation related to lift height, description
page
–

Vehicle speed is limited as follows (may vary depending on customers

request):
• Up to 3 m lift height (depending on the vehicle’s lift height), vehicle
speed is limited to 20 km/h.
• At maximum lift height, vehicle speed is limited to 5 km/h
• Between 3 m and maximum lift height (depending on the vehicle’s
lift height), the maximum speed of the vehicle is limited in propor-
tion to lift height.

8.5.21 Reversible driver’s station

Reversible driver’s station, description
page
–

Go to the Setup menus by pressing function key in this menu.

000056

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58 8 Control system – 8.5.21.2 Calibrating Reversible driver’s station

To access the setup menus, the service code has to be entered (au-
thorization required). Thereafter, the setups can be accessed to per-
form settings.
1 23
4 5

000060
Select Seat position.

(Scroll to the desired menu with function keys and and press
SEAT POSITION 1 2

to confirm.)
For Reversible driver’s station, it’s possible to choose calibration, see
004225
Calibrating Reversible driver’s station, description page 58).

8.5.21.2 Calibrating Reversible driver’s station

Calibrating Reversible driver’s station, description
page
–

Select Reversible driver’s station according to Reversible driver’s sta-

tion, description page 57.
Select calibration of Reversible driver’s station.
SEAT POSITION
004232

CALIBRATION

To calibrate the Reversible driver’s station, the parking brake must be

CALIBR 1(4) applied. Press to come further.
P-BRAKE MUST BE ON!
PRESS ENTER FOR
CALIBRATION!
008561

Turn the driver’s seat so that it is at the end position, facing straight
CALIBR 2(4) ahead. Press to confirm/save the position.
1104
FWD END 1104
POSITION (mV)
008562

Turn the driver’s seat so that it is in the position that should shift the
CALIBR 3(4) forward facing driver’s seat to a backwards facing driver’s seat. This
2464 should be within the range of 80-120°. Press to confirm/save the
SHIFT F/R 2464 position.
POSITION (mV)
008563

Turn the driver’s seat so that it is at the end position, facing straight be-
CALIBR 4(4) hind. Press to confirm/save the position.
3895
REV END 3895
POSITION (mV)
008564

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