H - 01 - ST D214 C236 H008 General Overview en Rev4

GENERAL OVERVIEW D214 / C236 / H008
SERVICE TRAINING 1
SERVICE TRAINING 2
SERVICE TRAINING 3
A 16-18 ton model is available, see the A238.

Note, an all new 23 ton is available now. This version has extra counter weight on the steer axle for
even better stability.
SERVICE TRAINING 4
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SERVICE TRAINING 6
New Hood, powertrain moved 150mm back
SERVICE TRAINING 7
New Hood, powertrain moved 150mm back

New Cooler with a 25% larger hydraulic cooler core.
SERVICE TRAINING 8
SERVICE TRAINING 9
C236: 3500mm has one 100ml/rev vdp and the 3750mm has two 75cml/rev vdps. Both frames
have a 38ml/rev gear pump for brake cooling and filtering, mounted on the engine.
SERVICE TRAINING 10
Same as on C214 and B236
SERVICE TRAINING 11
SERVICE TRAINING 12
Operator Compartment Tilt Options

Standard manual tilt
Optional electric powered tilt
Two hydraulic latches secure operator compartment in place.
Regardless of operator compartment tilt option:

All models have the manual pump.
All models have a pump handle positioned on the left hand side of the seat (not shown),
handle used to select direction of tilt.
All models have a safety latch that engages a locking plate during tilt, locking plate
welded to the frame.
Safety latch must be released when tilting the operator compartment over and
back.
If truck has electric powered tilt option and there is an electrical failure, the manual
pump can be used to tilt operator compartment.
SERVICE TRAINING 13
Hand pump oil John Deere J20C, oil fill and level plug is on top of hand pump
SERVICE TRAINING 14
SERVICE TRAINING 15
With the operator compartment tilted over components such as the steering orbitrol and
brake valve are accessible, other components that are accessible are:
Throttle pedal sensor all throttle / accelerator pedals have a 3 pin position sensor,
connects to CPS04 on frame harness CPS04 then to ECM CPS02.
Inching sensors connects to CPS32 on Cab Under floor harness then to transmission
controller CPR33.
ZF 4 pin sensor
Start enable switch same for all these models, connects to 2 spade terminals
TS34/TS35 on frame harness then to Cab Under floor harness CPR33.
Directional Control 2 options, lever or throttle / accelerator pedal
Directional Control Lever (standard) shifter lever on column provides means
to select direction and speed CPS29 connects to CPR30 on Steer Column
harness.
Monotrol Pedal Directional Control(optional) on accelerator pedal provides
means to select speed and direction connects to CPS31 Cab Under floor to
CPS30 on Steer Column harness.
SERVICE TRAINING 16
SERVICE TRAINING 17
Central Warning Lights

Lights illuminate / flash to draw operators attention to the instrument cluster to see which warning
light or gauge is flashing as an alert to the truck operating condition.
If a code is displayed on LCD, record the code.
Not all codes prompt central warning lights to flash.
Not all conditions prompt central warning lights to flash, for example some warning lights will be
illuminated but the central warning lights will not flash.
Warning lights that will illuminated but central warning lights not flashing
Seat Belt
Parking Brake
Wait to Start / Engine Warning
SERVICE TRAINING 18
Apply the parking brakes when the truck is off.

If parking brakes are not applied when the truck is off, parking brake solenoid remains engaged and
discharging the batteries.
If this occurs over an extended period of time, (weekend or holiday period), the truck will not start at
the beginning of the next shift.
SERVICE TRAINING 19
16 warning lights
All lights illuminate for 1 second after power up
Some lights flash when pre-set conditions occur, some remain constantly illuminated when pre-set conditions occur
Lights illuminate when respective pre-set conditions occur, for some the associated gauge and central warning lights will flash
Light may be for optional equipment not installed on truck
3 engine related warning lights illuminate when pre-set conditions occur, triggered by CAN signal from Cummins engine control module
See Cummins Engine Fault Code Guide 600 SRM/YRM 1101 for faults that trigger engine warning lights to illuminate
Engine Maintenance a few engine faults cause this light to illuminate
Wait to Start / Engine Warning
Most engine faults cause this light to illuminate
Illuminates for 15 seconds when engine temperature is below 27F (-3C), indicates grid heater is active, wait for light to go out before
attempting to start engine
Flashes when coolant temperature is above 230F (110C) and when air intake temperature is above 169F (76C)
Engine Stop critical engine faults such as low engine oil pressure, high transmission fluid temperature, and coolant temperature cause this light to
illuminate
2 transmission related warning lights illuminate when pre-set conditions occur, triggered by CAN signal from transmission controllers
ZF transmission - see ZF Fault Code Guide for faults that trigger transmission warning lights to illuminate
Transmission Failure / Malfunction most transmission faults cause this light to illuminate
Transmission Oil Pressure a few transmission faults cause this light to illuminate
Transmission Calibration illuminates when the transmission toggle switch in electronics compartment is switched to calibration mode, in calibration
mode, 24V is detected at pin 12 and light illuminates
Air Filter pin 9, digital signal, when air pressure drops the vacuum switch goes to ground causing the light to illuminate
Seatbelt pin 2, digital signal, light illuminates for 10 seconds after ignition ON, also illuminates to warn operator when out of seat with park brakes
released, sensor in seat, OPS
Hydraulic System Failure / Malfunction CAN signal from hydraulic controller

Most hydraulic faults cause this light to illuminate
Hydraulic Oil Filter Restriction (optional) CAN signal from hydraulic controller
Wet Brake Oil Temperature pin 6, digital signal, sensors mounted in each hub, when oil gets too hot light illuminates
Light may also illuminate in cold climates during start up, due to oil flow to axle being slow
Brake System Low Pressure pin 13, digital signal, applies when pressure gets too low light illuminates
Park Brake pin 7, digital signal, when park brake applied light illuminates
SERVICE TRAINING 20
SERVICE TRAINING 21
SERVICE TRAINING 22
LCD Instrument Cluster - Four modes:

Normal / Run Mode LCD displays truck hours in normal run mode, hours accumulate
only when engine RPM is above 300
Error Mode LCD enters Error Mode when active fault(s) occurs, remember not all
faults / truck conditions prompt a code to appear
LCD transitions between normal mode and error mode when active fault(s) are
present
Calibration Mode LCD enters calibration mode when toggle switch in electrical
compartment is moved to calibration position for calibrating transmission and/or inch
pedal sensor . we will discuss calibration in a later module
Error Log all received faults from engine, transmission, hydraulic controllers,
beginning with the most recent
Data stored for fault: code, hour meter reading of first occurrence, hour meter
reading of last occurrence, number of occurrences
Maximum number of occurrences for a fault, 255
Maximum number of faults stored, 18 to 36, depends on number of
occurrences
SERVICE TRAINING 23
Error Log Mode
To enter, apply park brake, ignition ON, engine off

Press and hold service switch 1 second, release 1 second, 1 appears on LCD
Press and hold service switch again 1 second, release 1 second, 2 appears on LCD
Press and hold service switch again 1 second, release 1 second, 3 appears on LCD
When pressing service switch, central warning lights flash and buzzer emits audible alarm
NOTE: DO NOT cycle key switch three times, this will cause ghost fault codes to appear. Cycling
key switch three times was the method for entering Error Log for previous models.
SERVICE TRAINING 24
Error Log Mode
If fault(s) stored, first fault and associated data to appear is most recent / newest fault
If multiple faults, Error Log automatically scrolls
If no faults stored, Clear appears on LCD
To clear Error Log repeat sequence of pressing and releasing service switch
Okclr appears on LCD when log is cleared
noclr appears when log is not cleared
Repeat sequence of pressing and releasing service switch until Okclr appears
To exit Error Log turn ignition switch to OFF, then to ON, leave in ON more than 2 seconds.
Starting engine or releasing park brake also exits Error Log mode
SERVICE TRAINING 25
Fault Codes
begin with a letter / letters to indicate which system has detected fault
E = Engine fault detected by Cummins engine controller
t = Transmission fault detected by transmission controller
h = Hydraulic fault detected by hydraulic controller
tE transmission Exceed Codes, they appear on LCD but are not stored in Error Log
Exceed codes transmission controller informing operator transmission is in a certain
state that is not a fault, but it may require operator attention, see Service Manual
Communication errors between cluster and controller caused by CANbus / controller errors appear
as:
E_COM, T_COM, H_COM, these can occur during controller software and parameter update not
stored in Error Log
Active faults can cause warning lights to illuminate, gauges to flash, central warning lights to flash,
alarm from buzzer
SERVICE TRAINING 26
Gauges
The cluster converts input CAN signals and analog signals to PWM signals for gauges
SERVICE TRAINING 27
Gauges
The cluster converts input CAN signals and analog signals to PWM signals for gauges
SERVICE TRAINING 28
Engine Coolant Gauge

CAN message to cluster, at approximately 230F / 110C gauge flashes red and warning light
flashes, shut engine down as soon as truck can be safely stopped
SERVICE TRAINING 29
Engine Oil Pressure Gauge

analog signal to pin 23 from resistive pressure sensor, when gauge flashes shut down engine as
soon as truck can be safely stopped, when engine RPM is below 300 gauge flashes
SERVICE TRAINING 30
Fuel Level Gauge

analog signal to pin 24 from fuel sender resistive sensor, gauge flashes red when tank level is
less than 10% capacity for more than 5 seconds, at this time LCD displays FUEL and central
warning lights flash
SERVICE TRAINING 31
Voltmeter
analog input to pin 1
gauge flashes red when:
a) Ignition switch in ON position, engine off
b) Engine running and RPM is less than 300
c) Engine running RPM greater than 300 and battery voltage below 22.5 volts for more
than 5 minutes
SERVICE TRAINING 32
Transmission Fluid Temperature Gauge:

CANbus signal from temperature sensor in sump area of transmissions
- gauge flashes red and warning light flashes
- shut engine down as soon as truck can be safely stopped
ZF gauge flashes red at 230F / 110C
SERVICE TRAINING 33
Inputs to cluster
CAN signals controllers engine, transmission, hydraulic
Digital signals seat switch (OPS), hydraulic brake oil, park brake, air filter restriction,
brake system pressure, transmission type input, transmission calibration
Analog signals battery voltage, engine coolant level, engine oil pressure, fuel level
Outputs from cluster to central warning lights and buzzer
SERVICE TRAINING 34
Electronic levers.
SERVICE TRAINING 35
Picture: FLT Joystick
SERVICE TRAINING 36
SERVICE TRAINING 37
Electronics Compartment - Located in the side console
Right hand side of the operator compartment

Protected by removable cover
Open operator compartments solid panel
Enclosed operator compartments panel with slots
SERVICE TRAINING 38
2 toggle switches
Switches up run mode

Switches down
Left switch transmission switch enables transmission calibration
Right switch hydraulic switch enables hydraulics to be operated with the seat
unoccupied
SERVICE TRAINING 39
SERVICE TRAINING 40
Auto Rev-up: standing still or Inching pedal at least pressed for 60%.
SERVICE TRAINING 41
Fuse and Relay Label. (This label is from 8-18 ton)
SERVICE TRAINING 42
24V to 12V DC DC Converter CPS107

Located below relay panel
Supplies 12V to optional 12V plug, optional radio, 12V relay
SERVICE TRAINING 43
Hydraulic Controller
Danfoss, standard for all truck configurations, same controller used for all configurations
50 pin connector, connects to CPS08 connector on Side Console harness
Programmable, provides diagnostics, set up
Controller loaded with 3 pre-set hydraulic system defined settings
Mode 1, Smooth or Soft
Mode 2, Medium
Mode 3, Rapid or Firm
To program controller, a ifak cable and a PC with Sauer Danfoss Plus+1 Guide Service Tool
software installed is required
Plus+1 Guide Service Tool software is downloadable from Hypass and Axcess On
Download automatically installs service software and drivers for ifak
Able to select settings, view diagnostics
SERVICE TRAINING 44
Transmission Controller Participant Guide page
Vendor ZF
Controller provides diagnostics
Software installed on PC required
ZF software - Testman
ZF Controller, EST 37A for WG211 Transmission

1 connector on controller, connects to CPS143 on Side Console harness
SERVICE TRAINING 45
SERVICE TRAINING 46
The Power Board has been added to protect electrical components from the environment. This is
an IP67 polycarbonate box with transparent cover that accommodates the main relay for the cab
power supply, fuses for alternator, grid heater and cab power supply, as well as fuses and relays for
the ECU and exhaust after treatment system power supply. All automotive fuses have a diagnostic
LED next to them that go on when a fuse is blown. The Power Board is located in the battery
compartment on all trucks.
SERVICE TRAINING 47
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To achieve stage IV emission standards Hyster further developed our EGR cooler system that has
proven to be very successful and combined it with SCR technology.
Before the fuel air mix is burned in the combustion chamber it will be cooled down in an EGR
cooler.
Lower temperature means less NOx will be produced, but on the other hand less soot particles can
be burned.
The exhaust gases will be split, a part of it are mixed with fresh air and re-enter the EGR cooler and
the combustion chamber.
Mixing fresh air with exhaust gases reduces the amount of oxygen and this also reduces the
amount of NOx produced (EGR= Exhaust Gas Recirculation).
The other part of the exhaust gases goes into the exhaust pipe where they will be mixed with
UREA and then enter a SCR catalyst.
In a chemical reaction more NOx is reduced in the catalyst.
In a next step the exhaust gases with the remaining soot enter a DOC (Diesel Oxidation Catalyst)
that further reduces the level of harmful substances by a chemical reaction before the gases are
finally emitted.
SERVICE TRAINING 53
Example from C236
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Oil level indicator glass is now protected by metal welded on the tank.
SERVICE TRAINING 63
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SERVICE TRAINING 71
PRLC and PRC => Planetary Rigid Axles
SERVICE TRAINING 72
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SERVICE TRAINING 75
Picture is from A238.

The axle is pin mounted to the frame with clamps underneath the frame.
Counterweight removal is therefore not required when removing the axle like on G008, G117, B917
and C222
SERVICE TRAINING 76
Pictures are from A238.
SERVICE TRAINING 77
Picture from A238
SERVICE TRAINING 78
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SERVICE TRAINING 80
Because of the interaction with the Danfoss hydraulic control unit, the pressure signal that the
attachment returned to the truck to request oil supply caused a conflict. The new attachments only
send a pressure signal for automatic locking (for attachment models that have automatic locking).
All other requests for oil supply to the attachment are handled by the hydraulic control unit. As a
result, attachments from C214 and D214 cannot be exchanged.
SERVICE TRAINING 81
SERVICE TRAINING 82
SERVICE TRAINING 83

H - 01 - ST D214 C236 H008 General Overview en Rev4

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H - 01 - ST D214 C236 H008 General Overview en Rev4

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Droits d'auteur :

Formats disponibles

GENERAL OVERVIEW D214 / C236 / H008

A 16-18 ton model is available, see the A238.

A 16-18 ton model is available, see the A238.

A 16-18 ton model is available, see the A238.

New Hood, powertrain moved 150mm back

New Hood, powertrain moved 150mm back

Same as on C214 and B236

Operator Compartment Tilt Options

Two hydraulic latches secure operator compartment in place.

Regardless of operator compartment tilt option:

Central Warning Lights

Apply the parking brakes when the truck is off.

Hydraulic System Failure / Malfunction CAN signal from hydraulic controller

LCD Instrument Cluster - Four modes:

Error Log Mode

To enter, apply park brake, ignition ON, engine off

Error Log Mode

If no faults stored, Clear appears on LCD

Engine Coolant Gauge

Engine Oil Pressure Gauge

Fuel Level Gauge

Transmission Fluid Temperature Gauge:

ZF gauge flashes red at 230F / 110C

Outputs from cluster to central warning lights and buzzer

Picture: FLT Joystick

Electronics Compartment - Located in the side console

Right hand side of the operator compartment

Switches up run mode

Fuse and Relay Label. (This label is from 8-18 ton)

24V to 12V DC DC Converter CPS107

Transmission Controller Participant Guide page

ZF Controller, EST 37A for WG211 Transmission

Example from C236

PRLC and PRC => Planetary Rigid Axles

Picture is from A238.

Pictures are from A238.

Picture from A238

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