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Kalmar DCD 200–300 Workshop Manual VDCD01.01GB – PDF DOWNLOAD
Kalmar DCD 200–300 Workshop Manual VDCD01.01GB – PDF DOWNLOAD
FILE DETAILS:
Kalmar DCD 200–300 Workshop Manual VDCD01.01GB – PDF DOWNLOAD
Language : English
Pages : 788
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Kalmar DCD 200–300 Workshop Manual VDCD01.01GB – PDF DOWNLOAD
Workshop manual DCD 200-300........................................................................................... 1 A Foreword............................................................................................................ 3 A Foreword........................................................................................................ 5 About the Workshop Manual..................................................................................... 5 General................................................................................................... 5 Workshop manual contents.................................................................................. 5 References between different information types............................................................ 6 Function group breakdown.................................................................................. 7 Conditions................................................................................................ 7 Storage................................................................................................... 7 About the machine version................................................................................. 7 Copyright................................................................................................. 7 Reading instructions.......................................................................................... 8 Warning information....................................................................................... 8 Important information..................................................................................... 8 Read the operator's manual/maintenance manual............................................................. 8 Optional equipment........................................................................................ 9 Function descriptions..................................................................................... 9 About the documentation....................................................................................... 12 Documentation sections.................................................................................... 12 Ordering of documentation................................................................................. 12 Feedback...................................................................................................... 13 Form for copying.......................................................................................... 13 B Safety.............................................................................................................. 15 Safety............................................................................................................ 17 General safety information.................................................................................... 17 Safety concerns everyone!................................................................................. 17 A near-accident is a warning signal!...................................................................... 17 Safety instructions........................................................................................... 18 General................................................................................................... 18 Service position.......................................................................................... 18 Hydraulic system, draining pressure....................................................................... 19 Oils...................................................................................................... 19 Fuel system............................................................................................... 20 Clothing etc.............................................................................................. 21 Several mechanics on the same machine..................................................................... 22 Working under machine..................................................................................... 22 Lifting heavy components.................................................................................. 23 Vibrations................................................................................................ 24 Noise..................................................................................................... 24 Solvents.................................................................................................. 24 Fire and explosion risks.................................................................................. 25 Fluid or gas under pressure............................................................................... 26 Coolant................................................................................................... 27 Refrigerant............................................................................................... 28 Air pollution............................................................................................. 28 Tensioned springs......................................................................................... 29 Electric motors........................................................................................... 29 Rotating components and tools............................................................................. 30 Tyre system............................................................................................... 31 Lifting equipment......................................................................................... 31 Environment................................................................................................... 32 General................................................................................................... 32 C Preventive maintenance.............................................................................................. 35 C Preventive maintenance.......................................................................................... 35 Preventive maintenance........................................................................................ 35 0 Complete machine.................................................................................................... 37 Complete machine.................................................................................................. 39 Complete machine, description ................................................................................ 39 Troubleshooting, general work instructions.................................................................... 40 Troubleshooting without an error code, example................................................................ 41 Troubleshooting with error code, example...................................................................... 41 Troubleshooting cable harness................................................................................. 43 Troubleshooting hydraulic hoses............................................................................... 44 1 Engine.............................................................................................................. 45 1 Engine.......................................................................................................... 47 1.1 Controls and instruments.................................................................................. 65 1.1.1 Ignition switch..................................................................................... 65 1.1.2 Accelerator pedal................................................................................... 65 1.2 Fuel system............................................................................................... 66 1.2.1 Fuel tank........................................................................................... 66 1.2.6 Sensor, fuel level.................................................................................. 66 1.3 Additional exhaust cleaning system........................................................................ 67 1.3.1 Combi-filter........................................................................................ 67 1.3.2 Catalyst............................................................................................ 69 1.6 Air intake and exhaust outlet............................................................................. 70 1.6.1 Air cleaning system................................................................................. 71 1.6.3 Exhaust system...................................................................................... 72 1.6.4 Intercooler......................................................................................... 74 1.6.8 Pipes and hoses..................................................................................... 75 1.7 Cooling system............................................................................................ 76 1.7.4 Radiator and expansion tank......................................................................... 77 1.7.8 Switch normally open (NO), coolant level............................................................ 79 1.7.10 Engine heater...................................................................................... 79 1.9 Control system engine..................................................................................... 80 1.9.1 Control unit engine (ECU 794)....................................................................... 80 1.9.3 Cables engine....................................................................................... 83 1.11 Start/stop............................................................................................... 93 1.11.2 Stopping device.................................................................................... 94 1.11.3 Automatic engine stop 5 minutes after driver’s seat is empty....................................... 94 1.11.5 Automatic engine power derate...................................................................... 94 2 Transmission........................................................................................................ 95 2 Transmission.................................................................................................... 97 2.1 Controls and instrument...................................................................................114 2.1.6 Gear and direction of travel selector...............................................................114 2.1.7 Inching.............................................................................................114 2.2 Torque converter/Clutch system............................................................................116 2.2.1 Flex plates.........................................................................................116 2.2.6 Switch normally closed (NC), disengagement..........................................................116 2.6 Lubrication...............................................................................................117 2.7 Cooling system............................................................................................118 2.7.3 Oil cooler..........................................................................................118 2.8 Transmission control system...............................................................................119 2.8.1 Transmission control unit (ECU 793).................................................................120 2.8.1.1 Connectors....................................................................................123 2.8.1.3 Suitable connectors...........................................................................125 2.8.2 Cable harness transmission..........................................................................126 2.8.3 Display and menues..................................................................................126 2.8.4 Reversing lock......................................................................................131 2.8.5 Manual shifting.....................................................................................132 2.8.6 Automatic transmission..............................................................................133 2.8.7 Inching.............................................................................................135 2.8.8 OptimumDrive........................................................................................138 2.8.9 Diagnostics.........................................................................................140 2.8.10 Calibration........................................................................................145 2.8.10.6 Calibration of transmission parameters.......................................................146 2.8.11 Service menues.....................................................................................149 3 Driveline/axle......................................................................................................151 3 Driveline/axle..................................................................................................153 3.2 Propeller shaft...........................................................................................154 3.3 Drive axle................................................................................................156 4 Brakes..............................................................................................................163 4 Brakes..........................................................................................................165 4.1 Controls and instruments..................................................................................165 4.1.1 Brake pedal.........................................................................................165 4.3 Power-assisted brake system...............................................................................167 4.3.1 Pump for accumulator charging, flushing/cooling system, brake and servo pressure control levers.....169 4.3.2 High-pressure filter................................................................................169 4.3.3 Main valve..........................................................................................170 4.3.3.1 Accumulator charging valve....................................................................170 4.3.3.2 Non-return valve..............................................................................170 4.3.3.3 Priority valve................................................................................170 4.3.3.4 Accumulator drain valve.......................................................................171 4.3.3.5 Parking brake valve...........................................................................171 4.3.4 Accumulator.........................................................................................171 4.3.5 Brake valve.........................................................................................171 4.3.6 Distribution block..................................................................................175 4.3.7 Switch normally Closed (NC), disengagement..........................................................177 4.3.8 Switch normally closed (NC), low brake pressure.....................................................178 4.3.9 Switch normally open (NO), brake lights.............................................................179 4.3.10 Wheel brake........................................................................................180 4.3.10.1 Disc pack....................................................................................181 4.3.10.2 Brake cylinder...............................................................................182 4.3.11 Pipes and hoses....................................................................................182 4.3.14 Shuttle valve dual brake pedals....................................................................182 4.5 Parking brake system......................................................................................184 4.5.1 Pump for accumulator charging, flushing/cooling system, brake and servo pressure control levers.....186 4.5.2 High pressure filter................................................................................186 4.5.3 Parking brake valve.................................................................................186 4.5.4 Parking brake unit..................................................................................187 4.5.4.1 Parking brake calliper........................................................................189 4.5.4.2 Parking brake pads............................................................................189 4.5.4.3 Parking brake disc............................................................................189 4.5.5 Switch normally open (NO), parking brake............................................................190 4.5.6 Pipes and hoses.....................................................................................190 4.8 Temperature control, cleaning and brake oil...............................................................191 4.8.1 Hydraulic oil tank..................................................................................191 4.8.2 Tank heater.........................................................................................191 4.8.3 Pump for accumulator charging, flushing-/ cooling system brake and servo pressure control levers....192 4.8.4 Accumulator charging valve..........................................................................192 4.8.5 Distribution block..................................................................................192 4.8.6 Wheel brake.........................................................................................192 4.8.7 Oil cooler..........................................................................................192 4.8.12 High pressure filter...............................................................................192 4.8.13 Pipes and hoses....................................................................................192 4.8.14 Hydraulic oil......................................................................................192 5 Steering............................................................................................................193 5 Steering........................................................................................................195 5.1 Controls and instruments..................................................................................195 5.1.1 Steering wheel and steering column..................................................................195 5.1.2 Mini-wheel..........................................................................................195 5.1.3 Lever steering......................................................................................200 5.2 Power-assisted system.....................................................................................206 5.2.1 Hydraulic oil pump, steering........................................................................213 5.2.2 Main valve (priority valve for steering)............................................................213 5.2.3 Steering valve......................................................................................214 5.2.4 Steering cylinder...................................................................................216 5.2.5 Steering axle cradle................................................................................217 5.2.6 Link arm............................................................................................218 5.2.7 Wheel spindle.......................................................................................219 5.2.8 Wheel hub...........................................................................................219 5.2.9 Sensor, wheel angle.................................................................................219 5.2.10 Control valve mini-wheel/lever steering............................................................221 5.2.11 Sensor, steering wheel movement....................................................................224 5.2.13 Pressure reducing valve............................................................................224 5.2.15 Directional valve reversible operator’s seat.......................................................225 5.2.16 Sensor reversible operator’s seat..................................................................225 5.2.17 Pipes and hoses....................................................................................226 6 Suspension..........................................................................................................227 6 Suspension......................................................................................................229 6.2 Suspension................................................................................................230 6.2.1 Steering axle cradle................................................................................231 6.2.2 Wheel spindle.......................................................................................233 6.2.3 Wheel hub...........................................................................................238 6.3 Tyre system...............................................................................................244 6.3.1 Tyres...............................................................................................245 6.3.2 Rims................................................................................................246 6.3.3 Nut, washer and clamp (wedge).......................................................................247 7 Load handling.......................................................................................................249 7 Load handling...................................................................................................251 7.1 Controls and instrumentation..............................................................................251 7.1.1 Control lever.......................................................................................251 7.2 Lifting/lowering..........................................................................................256 7.2.1 Hydraulic oil pump..................................................................................260 7.2.2 Accumulator.........................................................................................260 7.2.3 Main valve..........................................................................................260 7.2.4 Lift cylinder.......................................................................................261 7.2.5 Accumulator damping.................................................................................261 7.2.6 Mast................................................................................................263 7.2.7 Mast wheels.........................................................................................270 7.2.8 Chains..............................................................................................271 7.2.9 Chain wheels and hose wheels........................................................................272 7.2.10 Fork carriage......................................................................................273 7.2.11 Load control valve.................................................................................277 7.2.12 Pipes and hoses....................................................................................278 7.2.14 Support roller.....................................................................................278 7.2.15 Top support roller.................................................................................280 7.4 Side shift................................................................................................281 7.4.1 Hydraulic oil pump..................................................................................284 7.4.2 Accumulator.........................................................................................284 7.4.3 Main valve..........................................................................................284 7.4.4 Side shift cylinder.................................................................................285 7.4.5 Side shift frame....................................................................................287 7.4.6 Fork carriage.......................................................................................287 7.4.7 Pipes and hoses.....................................................................................287 7.5 Spreading.................................................................................................288 7.5.1 Hydraulic oil pump..................................................................................291 7.5.2 Accumulator.........................................................................................291 7.5.3 Main valve..........................................................................................292 7.5.4 Flow divider........................................................................................293 7.5.5 Spreading cylinder..................................................................................293 7.5.6 Fork carriage.......................................................................................294 7.5.7 Pipes and hoses.....................................................................................294 7.7 Tilt......................................................................................................295 7.7.1 Hydraulic oil pump..................................................................................298 7.7.2 Accumulator.........................................................................................298 7.7.3 Main valve..........................................................................................298 7.7.4 Load holding valve..................................................................................300 7.7.5 Tilt cylinder.......................................................................................301 7.7.6 Mast................................................................................................303 7.7.7 Pipes and hoses.....................................................................................303 7.8 Levelling.................................................................................................304 7.8.1 Hydraulic oil pump..................................................................................307 7.8.2 Accumulator.........................................................................................307 7.8.3 Main valve..........................................................................................307 7.8.5 Fork carriage.......................................................................................308 7.8.7 Pipes and hoses.....................................................................................308 7.9 Load carrier..............................................................................................309 7.9.1 Lift forks..........................................................................................309 7.10 Additional functions.....................................................................................311 7.10.1 Electric scales....................................................................................311 7.10.5 Side lift attachment...............................................................................312 8 Control system......................................................................................................313 8 Control system..................................................................................................315 8.2 Monitoring................................................................................................316 8.2.3 Speed limitation....................................................................................316 8.3 Error codes...............................................................................................317 8.4 Diagnostic test...........................................................................................318 8.4.1 ECU 790.............................................................................................321 8.4.1.1 View inputs...................................................................................321 8.4.1.2 View outputs..................................................................................322 8.4.1.4 Control outputs ..............................................................................323 8.4.2 ECU 792.............................................................................................327 8.4.2.1 View inputs...................................................................................327 8.4.2.2 View outputs..................................................................................328 8.4.2.4 Control outputs ..............................................................................329 8.4.3 ECU 793.............................................................................................330 8.4.4 ECU 796.............................................................................................331 8.4.4.1 View inputs...................................................................................331 8.4.4.2 View outputs..................................................................................332 8.4.4.4 Control outputs ..............................................................................333 8.4.5 Last alarms.........................................................................................337 8.5 Settings..................................................................................................340 8.5.1 ETC-Electronic Throttle Control (electronic throttle)...............................................340 8.5.1.1 Initiating ETC-Electronic Throttle Control....................................................340 8.5.1.2 Calibrate ETC-Electronic Throttle Control.....................................................341 8.5.2 Automatic shifting..................................................................................342 8.5.2.1 Initiating Automatic gear shift (ECU793)......................................................343 8.5.2.2 Calibrate Automatic gear shift , description..................................................344 8.5.4 Feedback lever steering.............................................................................346 8.5.4.1 Initiating Feedback lever steering ...........................................................346 8.5.4.2 Calibrating Feedback lever steering ..........................................................350 8.5.5 NON feedback lever steering.........................................................................351 8.5.5.1 Initiating NON feedback lever steering........................................................351 8.5.5.2 Calibrating NON feedback lever steering.......................................................351 8.5.6 Mini-wheel..........................................................................................351 8.5.6.1 Initiating Mini-wheel.........................................................................352 8.5.7 Electro-hydraulic servo.............................................................................353 8.5.7.1 Initiating Electro-hydraulic servo............................................................354 8.5.7.2 Calibrating Electro-hydraulic servo...........................................................357 8.5.8 Scale...............................................................................................358 8.5.8.1 Calibrating Scale.............................................................................359 8.5.9 Monitoring..........................................................................................359 8.5.9.1 Initiating Monitoring.........................................................................359 8.5.10 Pre-selected lifting height........................................................................360 8.5.10.1 Calibrating Pre-selected lifting height......................................................360 8.5.11 Tilt control.......................................................................................361 8.5.11.1 Calibrating Tilt control.....................................................................361 8.5.12 OptimumSpeed/OptimumRev............................................................................361 8.5.12.1 Initiating OptimumSpeed/OptimumRev...........................................................362 8.5.12.2 Calibrating OptimumSpeed/ OptimumRev.........................................................364 8.5.14 Clamp and lift function/lower and open function....................................................364 8.5.14.1 Initiating Clamp and lift function/lower and open function...................................364 8.5.14.2 Calibrating Clamp and lift function/ lower and open function.................................364 8.5.15 Automatic clamping function........................................................................365 8.5.15.1 Initiating Automatic clamping function.......................................................365 8.5.15.2 Calibrating Automatic clamping function......................................................366 8.5.16 Protection against loose chain tension.............................................................367 8.5.16.1 Initiating Protection against loose chain tension............................................367 8.5.16.2 Calibrating Protection against loose chain tension...........................................367 8.5.17 Protection against inadvertent opening of the clamp................................................367 8.5.17.1 Initiating Protection against inadvertent opening of the clamp...............................367 8.5.17.2 Calibrating Protection against inadvertent opening of the clamp..............................367 8.5.18 Automatic lowering stop............................................................................368 8.5.19 Driving interlock..................................................................................368 8.5.20 Speed limitation related to lift height............................................................368 8.5.21 Reversible driver’s station........................................................................369 8.5.21.2 Calibrating Reversible driver’s station......................................................369 8.6 Software..................................................................................................371 8.6.1 Kalmar Smart Link...................................................................................371 9 Frame, body, cab and accessories....................................................................................375 9 Frame, body, cab and accessories................................................................................379 9.1 Controls and instruments..................................................................................380 9.1.1 Multi-function lever................................................................................391 9.2 Safety and emergency equipment............................................................................397 9.2.1 Control switch......................................................................................397 9.2.2 Seat belt...........................................................................................397 9.2.3 Fire extinguisher...................................................................................397 9.2.4 Seat buzzer.........................................................................................398 9.2.5 Roof grating........................................................................................398 9.3 Seat......................................................................................................399 9.3.1 Seat cushion........................................................................................402 9.3.2 Back cushion........................................................................................404 9.3.3 Electric heater.....................................................................................404 9.3.4 Shock absorbers.....................................................................................404 9.3.5 Air suspension......................................................................................405 9.3.6 Compressed air-suspended seat.......................................................................405 9.3.7 Mechanical seat adjustment..........................................................................406 9.3.8 Passenger seat......................................................................................406 9.3.9 Reversible operator's seat..........................................................................407 9.3.10 Turnable operator's seat...........................................................................408 9.3.11 Armrest............................................................................................409 9.3.12 Direction valve, reversible driver’s seat..........................................................409 9.3.13 Sensor, reversible driver’s seat...................................................................409 9.3.17 Head restraint.....................................................................................409 9.4 Heating, ventilation and air conditioning.................................................................410 9.4.1 Fresh air / recirculation valve.....................................................................412 9.4.2 Air vents...........................................................................................412 9.4.3 Cab fan.............................................................................................413 9.4.4 Fresh air filter....................................................................................415 9.4.5 Heat exchanger heat.................................................................................416 9.4.6 Water valve.........................................................................................418 9.4.7 AC Compressor.......................................................................................419 9.4.8 Thermostat..........................................................................................421 9.4.9 Condenser unit......................................................................................422 9.4.10 Expansion valve....................................................................................424 9.4.11 Evaporator.........................................................................................425 9.4.12 Sensor for ECC.....................................................................................426 9.4.13 Control unit ECC...................................................................................427 9.4.14 Air distributor....................................................................................427 9.4.15 Fine filter........................................................................................428 9.4.16 Pause heater.......................................................................................428 9.4.18 Cabin heater.......................................................................................428 9.4.20 Cooling unit.......................................................................................429 9.4.21 Particle and moisture filter.......................................................................429 9.4.22 Actuator motor.....................................................................................431 9.5 Wiper/washer system.......................................................................................434 9.5.1 Wiper front.........................................................................................434 9.5.2 Wiper roof..........................................................................................434 9.5.3 Wiper rear..........................................................................................434 9.5.4 Washer motor and reservoir..........................................................................434 9.5.5 Wiper motor, front..................................................................................435 9.5.6 Wiper motor, roof...................................................................................436 9.5.7 Wiper motor, rear...................................................................................439 9.6 Lighting system...........................................................................................441 9.6.1 Headlights..........................................................................................442 9.6.2 Position light......................................................................................442 9.6.3 Tail light..........................................................................................442 9.6.4 Brake light.........................................................................................443 9.6.5 Reversing light.....................................................................................443 9.6.6 Driving direction indicator.........................................................................443 9.6.7 Warning lamp, Hazard................................................................................443 9.6.8 Rotating beacon.....................................................................................444 9.6.9 Working lights, mast................................................................................446 9.6.10 Working lights, cab................................................................................446 9.6.11 Interior lighting..................................................................................446 9.6.12 Working lights, fenders............................................................................446 9.6.13 Engine room lighting...............................................................................447 9.7 Signalling system.........................................................................................448 9.7.1 Horn................................................................................................448 9.7.2 Warning lamp, Hazard................................................................................448 9.7.3 Rotating beacon.....................................................................................448 9.7.4 Warning parking brake...............................................................................448 9.7.5 Reversing alarm.....................................................................................449 9.7.6 Flashing brake light for reversing..................................................................449 9.8 Entertainment and communication...........................................................................450 9.8.1 Radio with CD.......................................................................................450 9.8.2 Communication radio.................................................................................451 9.8.3 Telephone...........................................................................................451 9.8.4 Terminal............................................................................................452 9.8.5 Screen..............................................................................................452 9.8.6 Computer............................................................................................452 9.8.7 Voltage converter...................................................................................452 9.9 Glass/windows/mirrors.....................................................................................454 9.9.1 Windscreen..........................................................................................454 9.9.2 Side window.........................................................................................454 9.9.3 Roof window.........................................................................................454 9.9.4 Rear window.........................................................................................454 9.9.5 Rear-view mirror....................................................................................455 9.9.6 Protective screen in front of windscreen............................................................455 9.9.7 Window moulding.....................................................................................455 9.9.8 Reversing camera....................................................................................458 9.9.8 Monitor, reversing camera...........................................................................459 9.10 Cab structure and suspension.............................................................................460 9.10.1 Cab frame..........................................................................................460 9.10.2 Doors..............................................................................................460 9.10.3 Cab mounting.......................................................................................461 9.10.4 Cab tipping........................................................................................462 9.10.5 Door stop..........................................................................................463 9.10.6 Roof and door mouldings............................................................................464 9.10.7 Cab tipping cylinder...............................................................................464 9.11 Cab interior.............................................................................................470 9.11.1 Instrument and control panels......................................................................470 9.11.2 Interior trim components, plastic..................................................................471 9.11.3 Interior trim components, textile..................................................................475 9.11.4 Floor covering.....................................................................................475 9.11.5 Insulation.........................................................................................476 9.11.6 Sun blinds.........................................................................................476 9.11.7 Terminal console...................................................................................476 9.11.8 Writing desk.......................................................................................476 9.11.9 Compartment for A4 papers..........................................................................476 9.11.10 Holder for pump lever.............................................................................476 9.12 Frame....................................................................................................477 9.13 Body.....................................................................................................478 9.13.1 Fenders............................................................................................478 9.13.2 Hood engine compartment............................................................................478 9.13.3 Footstep...........................................................................................480 9.13.4 Counterweight......................................................................................480 9.13.5 Battery compartment................................................................................481 9.13.7 Mud guards.........................................................................................481 9.13.8 Tool kit...........................................................................................481 9.13.9 Lifting lugs.......................................................................................482 9.14 Central lubrication......................................................................................483 9.14.1 Pump unit..........................................................................................483 9.14.2 Distribution block.................................................................................484 9.14.3 Lines..............................................................................................484 9.14.4 Grease nipples.....................................................................................484 9.15 Paint/coatings...........................................................................................485 10 Common hydraulics..................................................................................................487 10 Common hydraulics..............................................................................................489 10.2 Security valves..........................................................................................489 10.2.1 Accumulator drain valve............................................................................489 10.2.2 Pipes and hoses....................................................................................489 10.3 Tanks and accumulators...................................................................................490 10.3.1 Tank...............................................................................................490 10.3.2 Accumulator........................................................................................491 10.3.3 Sensor, low brake pressure.........................................................................494 10.3.4 Pipes and hoses....................................................................................494 10.4 Pumps....................................................................................................495 10.4.1 Gear pump with fixed displacement..................................................................495 10.4.3 Pipes and hoses....................................................................................497 10.5 Hoses, pipes and valves..................................................................................498 10.5.1 Pipes and hoses....................................................................................498 10.5.2 Main valve.........................................................................................499 10.5.3 Priority valve.....................................................................................505 10.5.5 Proportional valve.................................................................................505 10.6 Temperature control, cleaning and hydraulic oil..........................................................506 10.6.1 Tank heater........................................................................................508 10.6.2 Hydraulic oil cooler...............................................................................510 10.6.3 Sensor hydraulic oil temperature...................................................................510 10.6.4 Switch (NC) cooling fan............................................................................511 10.6.5 Cooling fan........................................................................................511 10.6.6 Thermal by-pass valve..............................................................................512 10.6.7 Breather filter hydraulic oil tank.................................................................512 10.6.8 High-pressure filter...............................................................................513 10.6.9 Hydraulic oil......................................................................................513 10.6.11 Pipes and hoses...................................................................................513 10.7 Auxiliaries..............................................................................................514 10.7.1 Hydraulic cylinders................................................................................514 11 Common electric....................................................................................................523 11 Common electric................................................................................................525 11.1 Controls and instrumentation.............................................................................525 11.1.1 Hour meter.........................................................................................525 11.2 Electric protection......................................................................................526 11.2.1 Battery disconnector...............................................................................526 11.2.2 Fuses..............................................................................................527 11.3 Batteries................................................................................................529 11.3.1 Start battery......................................................................................529 11.4 Alternator...............................................................................................531 11.4.1 Alternator.........................................................................................531 11.5 Distribution of electricity..............................................................................532 11.5.1 Power supply.......................................................................................533 11.5.1.1 Battery voltage, terminal 30 volts...........................................................534 11.5.1.2 Ignition voltage, terminal 15 volts..........................................................534 11.5.1.3 Frame connections............................................................................534 11.5.2 Electrical distribution box........................................................................535 11.5.3 Control units......................................................................................554 11.5.3.1 Terminal EDU 795.............................................................................555 11.5.3.2 Control unit ECU 790.........................................................................556 11.5.3.3 Control unit ECU 796.........................................................................561 11.5.3.2 Control unit ECU 792.........................................................................565 11.5.4 Operation, electrical system ......................................................................568 11.5.5 Cables.............................................................................................568 11.6 Communication............................................................................................569 11.6.1 CAN-bus............................................................................................570 11.6.2 Redundant CAN-bus..................................................................................572 11.6.3 CAN-bus driveline..................................................................................573 D Error codes.........................................................................................................575 Error codes.......................................................................................................577 Error codes, explanation......................................................................................577 Error code menu, description..................................................................................578 Reading out error code........................................................................................581 1 Engine..........................................................................................................583 Error codes engine, general...................................................................................583 Error codes engine alternative Volvo TAD750VE.................................................................584 Error codes engine alternative Cummins QSB6.7.................................................................596 2 Transmission....................................................................................................613 Error codes transmission......................................................................................613 8 Control system..................................................................................................626 Error codes machine...........................................................................................626 9 Frame, body, cab and accessories................................................................................636 9.4 Heating, ventilation and air conditioning.................................................................636 ECC: Reading out error code...............................................................................636 ECC: Error code table.....................................................................................637 E Schematics..........................................................................................................639 10 Common hydraulics..............................................................................................641 Hydraulic diagrams, compilation...............................................................................641 Hydraulic diagram A06195.0700.................................................................................642 Hydraulic diagram A06195.0600.................................................................................644 11 Common electrics...............................................................................................646 Circuit diagram, description .................................................................................646 Component designations........................................................................................647 Circuit diagrams, compilation.................................................................................648 Wiring Diagram....................................................................................................651 A49842.0100...................................................................................................651 0 | WIRING DCE 50-........................................................................................651 0.0_1 | WIRING CROSS REFERENCE ECU 790....................................................................652 0.0_2 | WIRING CROSS REFERENCE ECU 793....................................................................653 0.0_3 | WIRING CROSS REFERENCE ECU 796....................................................................654 0.0_4 | WIRING CROSS REFERENCE ECU 796....................................................................655 0.0_5 | WIRING CROSS REFERENCE ECU 792....................................................................656 1.0_A | WIRING MOTOR VOLVO TAD750/650.....................................................................657 1.0_B | WIRING ENGINE CUMMINS.............................................................................658 1.0_C | WIRING PERKINS/CATERPILLAR........................................................................659 2.0_A1 | WIRING GEAR CHANGING, ECU790.....................................................................660 2.0_A2 | WIRING EXTRA FWD/REV.............................................................................661 2.0_A3 | WIRING GEAR CHANGING, AUT/ECU793.................................................................662 2.0_A4 | WIRING GEAR CHANGING, ECU793.....................................................................663 2.0_B1 | WIRING HYDROSTATIC TRANSMISSION..................................................................664 2.0_B2 | WIRING HYDROSTATIC TRANSMISSION..................................................................665 2.0_B3 | WIRING, HYDROSTATIC TRANSMISSION.................................................................666 2.0_C1 | WIRING GEAR CHANGING ZF..........................................................................667 2.0_C2 | WIRING GEAR CHANGING ZF..........................................................................668 4.0_1 | WIRING CAB........................................................................................669 4.0_2 | WIRING CAB TDS....................................................................................670 4.0_3 | WIRING MONITORING BRAKEPRESSURE...................................................................671 4.5 | WIRING PARKING BRAKE................................................................................672 5.2_1A | WIRING STEERING..................................................................................673 5.2_1B | WIRING STEERING TDS..............................................................................674 5.2_2A | WIRING STEERING..................................................................................675 5.2_2B | WIRING STEERING, TDS.............................................................................676 7.0_1 | WIRING SERVO & HYDRAULICS.........................................................................677 7.0_2 | WIRING SERVO AND HYDRAULICS.......................................................................678 7.0_3 | WIRING SERVO & HYDRAULICS,TDS.....................................................................679 7.0_4 | WIRING ECU796, JOYSTICK...........................................................................680 7.0_5A | WIRING ECU796 JOYSTICK 2.........................................................................681 7.0_5B | WIRING ECU796 JOYSTICK 2 TDS.....................................................................682 7.2_1 | WIRING LIFTH.TILTANG.AUTOH.CL.PRES................................................................683 7.2_2A | WIRING ATTACHMENT SENSORS........................................................................684 7.2_2B | WIRING ATTACHMENT VALVES.........................................................................685 7.2_3 | WIRING INDICATION LAMPS...........................................................................686 7.2_4 | WIRING SWITCHES PAPER FUNCT.......................................................................687 7.2_5A | WIRING STOP LOWER................................................................................688 7.2_6 | WIRING OPTI SPEED/REV.............................................................................689 7.10_1 | WIRING ELECTRONIC SCALE..........................................................................690 7.10_2 | WIRING OVERLOAD PROTECTION.......................................................................691 8.2_1 | WIRING DATA COM. RED CAN..........................................................................692 8.2_2 | WIRING MONITORING.................................................................................693 8.2_3 | WIRING SENS., SPEED & ENGINE REV..................................................................694 8.2_4 | WIRING DATA COM. J1939............................................................................695 8.2_5 | WIRING DATA COM...................................................................................696 9.1 | WIRING SENSORS/INSTRUMENT...........................................................................697 9.3_1 | WIRING CABIN, SEAT ROTATION.......................................................................698 9.3_2 | WIRING SEAT ROTATION..............................................................................699 9.3_3 | WIRING SEAT UP/DOWN...............................................................................700 9.3_4 | WIRING SPEED CONTROL..............................................................................701 9.4_1 | WIRING ECC........................................................................................702 9.4_2 | WIRING HEATING/AC.................................................................................703 9.4_3 | WIRING HEATING/AC FLEXCAB.........................................................................704 9.4_5 | WIRING HEATING/AC.................................................................................705 9.4_6 | WIRING ECC FAN....................................................................................706 9.4_7 | WIRING PAUSHEAT(OPT)..............................................................................707 9.5_1 | WIRING WIPERS.....................................................................................708 9.6_1 | WIRING HEAD LIGHTS................................................................................709 9.6_2 | WIRING HEAD LIGHTS................................................................................710 9.6_3A | WIRING HEADLIGHTS................................................................................711 9.6_3B | WIRING HEADLIGHTS, TDS...........................................................................712 9.6_4 | WIRING HEAD LIGHTS TDS............................................................................713 9.6_5A | WIRING HEAD LIGHTS REAR..........................................................................714 9.6_5B | WIRING HEAD LIGHTS REAR..........................................................................715 9.6_5C | WIRING HEAD LIGHTS REAR..........................................................................716 9.6_6 | WIRING WORKING LIGHT..............................................................................717 9.6_7 | WIRING WORKING LIGHT..............................................................................718 9.6_8A | WIRING WORKING LIGHT.............................................................................719 9.6_8B | WIRING WORKING LIGHT, TDS........................................................................720 9.6_9 | WIRING LIGHT, ENGINE BAY..........................................................................721 9.8_1 | WIRING CABIN......................................................................................722 9.8_2 | WIRING COMPRESSOR HORN............................................................................723 9.14 | WIRING, OPTION.....................................................................................724 11.5_1 | WIRING POWER SUPPLY..............................................................................725 11.5_2 | WIRING POWER SUPPLY, FUSES.......................................................................726 11.5_3 | WIRING POWER SUPPLY, FUSES.......................................................................727 11.5_4 | WIRING POWERSUPPLY ECU 792.......................................................................728 11.5_5 | WIRING POWER SUPPLY, ECU793......................................................................729 11.5_6 | WIRING POWER SUPPLY, ECU/EDU.....................................................................730 Wiring diagram, optional equipment................................................................................731 A50617.0100...................................................................................................731 List of components................................................................................................733 F Technical data......................................................................................................751 Technical data....................................................................................................753 Specifications for data and volume............................................................................753 Specifications for lift capacity and dimensions...............................................................757 Recommended oils and lubricants...............................................................................759 Tightening torques, recommendations...........................................................................761 Tightening torques, ORFS- couplings...........................................................................762 Unit explanations.............................................................................................764 Conversion table, SI-units....................................................................................765 Conversion table, length......................................................................................766 Conversion table, area........................................................................................766 Conversion table, volume......................................................................................766 Conversion table, weight......................................................................................767 Conversion table, pressure....................................................................................767 G Terminology and index...............................................................................................769 Terminology and index.............................................................................................771 Explanation...................................................................................................771 Index.........................................................................................................774
DESCRIPTION:
Kalmar DCD 200–300 Workshop Manual VDCD01.01GB – PDF DOWNLOAD
Foreword:
About the Workshop Manual:
General
Thank you for choosing Kalmar Industries as your machine supplier.
We hope that we’ll meet your expectations.
Workshop manual contents:
- The workshop manual contains information for corrective maintenance (replacement of components) and complements the maintenance manual. Accompanying the workshop manual is supplier documentation for engine, transmission and drive axle.
- Where practicable, please refer from the workshop manual to the maintenance manual and supplier documentation to avoid duplicated information. The workshop manual is divided into the following sections.
General safety information:
The safety information concerns everyone who works with the machine! Persons who do not follow the safety instructions given in this manual must make absolutely sure that the work is performed without risks of personal injury and without risk of damage to machine or machine property!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and work carefully. Do not take any risks!
Kalmar Industries has in this publication documented and warned for situations and risks that may occur in connection with using as well as service/repairs of the machine during normal circumstances. That’ s why it’s important that all who work with the machine, or repair/ service the machine read and follow the information in the manuals.
IMAGES PREVIEW OF THE MANUAL:
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