DCE90-180

Kalmar Control
System (KCS)

Paul Stancer
 KCS CAN Overview

CAN J1939
ECU793 250kbit/s ECU794
Gearbox Engine

EDU795
Terminal
RS232

CAN KINGDOM
ECU790 125kbit/s ECU796
General Hydraulic
 J1939 CAN
ECU793 ECU794

EDU795
EDU 795
CAN KINGDOM
ECU790 ECU796

 Graphic display

 6pcs function buttons

 Information and alarm

 Initiation of functions

 Diagnostics

 Link the control system

 J1939 CAN
ECU793 ECU794

EDU795 ECU 790

CAN KINGDOM
ECU790 ECU796

 Automatic gear change with

Clark Transmission

 Monitoring

 ETC(electronic throttle control)

 Hydrostatic drive

 Opti Speed

 Opti Rev
 J1939 CAN
ECU793 ECU794
ECU 793
EDU795

CAN KINGDOM
ECU790 ECU796
 Control of engine speed and
brakes

 Functions:
 Manuell/automatic gear change
 Speed limit
 Electronic inching
 Optidrive
 ”Limp Home”
 Shut down
 Diagnostic
 Statistics
 J1939 CAN
ECU793 ECU794

EDU795
ECU 794
CAN KINGDOM
ECU790 ECU796

 Volvo ECM

 Cummins ECM

 Functions:
 Electronic controlled
 monitoring
 diagnostic
 Calibration
 J1939 CAN
ECU793 ECU794

EDU795
CAN-bus
CAN KINGDOM
ECU790 ECU796

 Communication between
the units
 High reliability
 Standard specifies:
 Twisted pair leads
 Design of message
 Terminating resistors to
avoid deformation of pulse
trains
Menu system

 Interface with the operator

 ISO-symbols to obtain
language independence

 6 functions keys for navigation

 Main functions
 set-up
 initiation
 calibration
Alarm

 Errors and messages

 4 information fields:
 B: type of alarm:
 stop
 warning
 information
 C: Error code
 D: Type of error
 E: Where it occurred
Functions KCS

 Automatic  Control up/down gear change

Gear Change
 Control of input signals
Clark
Transmissions  Easier driving

 FT2000  Extend life time

 HR28000
 Possibility to limit gear change
Functions KCS

 Reversing
lock
Functions KCS

 Monitoring
Functions KCS
ETC = Electronic Throttle Control
 ETC Replace cable
Reduce engine speed
Reset Service Interval

Code 45454 to rest

Code 44241 Master on
first rest from 50 to 500
hours
Diagnostics ECU790
Diagnostics ECU790 View Digital Inputs
Diagnostics ECU790 View Digital Inputs 1/7

1.09 Gear Pos 2 1.13 REV Pos Input

1.10 Gear Pos 1 1.14 Parking Brake pressure
1.11 Seat Turn CW 1.15 Inching De Clutch
1.12 FWD Pos Input 1.16 Speed Limit 2 Optional
Diagnostics ECU790 View Digital Inputs 2/7

1.17 Ign Key Pos 3 (Crank) 1.21 Function 5

1.18 Seat Turn CCW 1.22 Brake Pressure
1.19 Seat Contact 1.23 Parking Brake Switch On
1.20 Spread/Fork/Diff Interlock
Diagnostics ECU790 Reostat Inputs 3/7

2.19 Not Used 2.08 Fuel level

2.20 Not Used
2.21 Temp Hydrostat Oil
2.22 Out Door Temp
Diagnostics ECU790 View ANA Inputs 4/7

1.01 24v Power Supply 1.26 ACC Pedal

1.07 24v CPU LEFT 1.27 Left Pedal CH1
1.08 24v CPU RIGHT 1.28 Pressure Lift Lever
1.24 5v ANA Ref 1.29 Scale Load Cell Left
Diagnostics ECU790 View ANA Inputs 5/7

1.30 Scale Load Cell Right 1.34 Pressure REV

1.31 Load Cell Tilt 1.37 Seat Position
1.32 Direction Hydrostatic Motor 1.38 Coolant Level
1.33 Pressure FWD 1.39 Right Pedal 180/40 DEG
Diagnostics ECU790 View ANA Inputs 6/7

1.40 Left Pedal 180/40 DEG

1.41 Left Pedal CH2
1.42 ANA Input
Diagnostics ECU790 View Freq. Inputs 7/7

2.01 Vehicle Speed Hz

2.03 RPM Sensor Engine Hz
2.05-06 Pulse
 DCE90-180
Diagnostics ECU
D793 DANA VFS

Paul Stancer
Diagnostics ECU793
Diagnostics ECU793 DANA VFS Booster Type

Note the following, Use Dana wiring diagrams to follow the

Dana Diagnostic pages.
Example W/4206981 for TE17 VFS Type
 M

M M M M M

S S S S S S

S S S S S

S S S S
S
S
Power up
+ S S S S S
... ... ... ...
S S S S S

S S S S
 M

M M M M M

Power up Display Test

+ S

 Note : for the firmware version, the

display is using a scrolling text
moving to the left (continuously).
 M

M M M M M

S 0 2 4 6 8 10 12

1 3 5 7 9 11 13

Digital Input Reference

S
...
S Analogue
Digital Inputs 0-9 or Digital
0 2 4 6 8 10 12
1 3 5 7 9 11 13
S
 M

M M M M M

Lo = Input not
active

Channel Reference Wire Pin Function APC200 ECU790 Type

0 12 A12 B2 1-2 shift lever Lo /Hi 01:10 DIG
1 13 A13 C2 2-3 shift lever Lo /Hi 01:09 DIG
2 14 A14 D2 Seat Orientation Lo /Hi 01:37 DIG
3 17 A17 G2 Neutral Lo /Hi Via CAN DIG
4 18 A18 H2 Forwards Input (Dana) Lo /Hi 01:12 DIG
5 19 A19 J2 Reverse Input (Dana) Lo /Hi 01:13 DIG
6 43 B13 L3 Inching Enable / Disable Lo /Hi Via CAN DIG
7 44 B14 M3 Automatic / Manual Lo /Hi Via CAN DIG
8 45 B15 N3 Parking Brake On/Off Lo /Hi 01:23 DIG
9 46 B16 P3   Lo /Hi X DIG
10 11 A11 A2 Pressure feedback sensor Lo /Hi Via CAN AN or DIG
11 28 A28 H3 Temp ( Combined with Speed sensor) Lo /Hi Via CAN AN or DIG
12 29 A29 J3 Convertor Temp Switch Lo /Hi Via CAN AN or DIG
13 47 B17 R3 Brake pedal Lo /Hi 01:27 AN or DIG
 M

M M M M M

Channel Reference Wire Pin Function APC200 ECU790 Type

0 12 A12 B2 1-2 shift lever Lo /Hi 01:10 DIG
1 13 A13 C2 2-3 shift lever Lo /Hi 01:09 DIG
2 14 A14 D2 Seat Orientation Lo /Hi 01:37 DIG
3 17 A17 G2 Neutral Lo /Hi Via CAN DIG
4 18 A18 H2 Forwards Input (Dana) Lo /Hi 01:12 DIG
5 19 A19 J2 Reverse Input (Dana) Lo /Hi 01:13 DIG
6 43 B13 L3 Inching Enable / Disable Lo /Hi Via CAN DIG
7 44 B14 M3 Automatic / Manual Lo /Hi Via CAN DIG
8 45 B15 N3 Parking Brake On/Off Lo /Hi 01:23 DIG
9 46 B16 P3   Lo /Hi X DIG
10 11 A11 A2 Pressure feedback sensor Lo /Hi Via CAN AN or DIG
11 28 A28 H3 Temp ( Combined with Speed sensor) Lo /Hi Via CAN AN or DIG
12 29 A29 J3 Convertor Temp Switch Lo /Hi Via CAN AN or DIG
13 47 B17 R3 Brake pedal Lo /Hi 01:27 AN or DIG
 M

M M M M M

Analogue S
Inputs No . Meaning the
value is in 

S
...
S

1st Value (K orV)

Of the 1st 4 analogue
inputs S A.meaning the
Analogue inputs 3 on Value is in Volts
wire 34
(47-30 pins on connector
A=B17)
 M

M M M M M

Channel Reference Wire Pin Function APC200 ECU790 Type

0 11 A11 A2 Pressure Feedback Yes N/A oHms
1 28 A28 H3 Temp sensor from Engine Speed Sensor Yes N/A oHms
2 29 A29 J3 Torque Convertor Out temp Yes N/A mV
3 47 B17 R3 Brake Pedal Option 01:27 mV
4 32 B02 M1 Reference Voltage H bridge Throttle Pedal Option Option  
5 34 B04 P1 Auto/ Manual switch Option Option  
6 36 B06 S1 Input Throttle pedal Option 01:26  
 M

M M M M M

Speed Sensor S
Test

C informs the sensor is a

current sensor. Valve is
S
... shown in Hz or KHz
S ( Ex.:C2.24)

1st value (KHz) of each

Speed sensor 0
of the 4 speed sensors
on Wire 22
S
 M

M M M M M

Channel Reference Wire Pin Function APC200 ECU790 Type

0 22 A22 B3 Drum Speed Yes No Current
1 24 A24 D3 Output Speed Yes No Current
2 26 A26 F3 Engine Speed Sensor Yes No Current
3 41 B11 R2 Turbine Speed Yes No Current
 M

M M M M M

Analogue Output
S
3 on wire 8

Output Test
S

Note :
0 to 6 are
Analogue
S
Outputs.
...
Analogue Output and
Current of 997mA S
7 to 10 are
Digital
Digital output 1
Outputs.
(7-6=1) on wire 10
Output Active
S
 M

M M M M M

Channel Reference Wire Pin Function APC200 ECU790 Type

0 2  A02 B1 Forwards (Dana), Kalmar Reverse Yes
. No mA
1 4 A04 D1 2nd VFS Yes No mA
2 6 A06 F1 Reverse (Dana), Kalmar Forwards Yes No mA
3 8 A08 H1 1st/3rd VFS Yes No mA
4 31 B01 L1 H Bridge Step Motor Yes No PWM
5 33 B03 N1 H Bridge Step Motor Yes No PWM
 M

M M M M M

Channel Reference Wire Pin Function APC200 .

ECU790 Type
6 35 B05 R1 Brake Valve ( OptiDrive Option) Yes No  
7 10 A10 K1 Drive Ok Solenoid Yes No Dig
8 15 A15 E2 4th VFS ( Not Fitted) Yes No Dig
9 16 A16 F2 1st/3rd Select Solenoid Yes No Dig
10 20 A20 K2 Drive solenoid ( Pulled to ground) Yes No Dig
 M

M M M M M

Voltage Test
Ignition Switched
Power S

22.7 Volts
S

Voltage Sensor
Sensor Supply Power Supply
Voltage 8.1v
 DCE90-180
Calibration D793
VFS Booster Type

Paul Stancer
Calibration ECU793 DANA VFS Booster Type

Scroll to Kalmar Man with

Spanner

Enter Master Code 44241

Press Enter Button

Calibration ECU793 DANA VFS Booster Type

Press Enter Button

Press Button until

page 2(2) Automatic Gear
Shift ECU793 Calibration

Press Enter Button

Calibration ECU793 DANA VFS Booster Type

Press Enter Button

You are now in the APC 200

Calibration Menu.

Use the Button M and S to

Jump from Menu to Menu or S
to Select. When using Kalmar
Display M is and S is
Calibration ECU793 DANA VFS Booster Type

Use the Button to drop

down to the Menu Headings
until you find “hEAt”

Press the Button to select

“hEAt” Mode,

You are now in “hEAt” up mode.

The APC controller has selected the highest
possible gear for you to drive against the
foot brake.
Calibration ECU793 DANA VFS Booster Type
Release the Parking Brake and apply the
Foot brake and then select forwards drive

Drive against the Foot Brake as shown below

Calibration ECU793 DANA VFS Booster Type
Continue until the temp shows 65Degrees
At this point, Select Neutral, Apply Parking Brake
And the press the Button.

Scroll through the menu headings using the Button until you find
“trAn” .

At this point select the Button to

select calibration.

This Screen will appear, that means now

Select Forward Drive. This will start the
Calibration. Once started you can select
Neutral. (Note Reverse will stop the Calibration)
Calibration ECU793 DANA VFS Booster Type
 Calibration ECU793 DANA VFS Booster Type

This Process will continue until all five clutches have been selected
 Calibration ECU793 DANA VFS Booster Type

C5.N2 is the last Phase for a 3 speed transmission

 Calibration ECU793 DANA VFS Booster Type

When “donE” Appears, Turn off Key – Calibration is complete.