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Kalmar Empty Container Handler 8-9T DCT80-90 Workshop Manual – PDF DOWNLOAD
Kalmar Empty Container Handler 8-9T DCT80-90 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Kalmar Empty Container Handler 8-9T DCT80-90 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 838
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Kalmar Empty Container Handler 8-9T DCT80-90 Workshop Manual – PDF DOWNLOAD
A Foreword.......................................................... 5 A Foreword...................................................... 7 About the Workshop Manual.................................. 7 Reading instructions....................................... 8 About the documentation.................................... 16 Feedback................................................... 17 B Safety............................................................ 19 B Safety........................................................ 21 General safety information................................. 21 Safety instructions........................................ 22 Environment................................................ 38 C Preventive maintenance............................................ 41 C Preventive maintenance........................................ 41 0 Complete machine.................................................. 43 0 Complete machine.............................................. 45 1 Engine............................................................ 53 1 Engine........................................................ 55 1.1 Controls and instruments................................ 72 1.1.1 Ignition.......................................... 72 1.1.2 Accelerator....................................... 72 1.2 Fuel system............................................. 73 1.2.1 Fuel tank......................................... 73 1.2.2 Sensor fuel level................................. 74 1.2.5 Make-contact (closing switch) water in fuel....... 74 1.6 Air intake and exhaust outlet........................... 75 1.6.1 Air cleaning system............................... 75 1.6.3 Exhaust system.................................... 75 1.6.4 Intercooler....................................... 76 1.7 Cooling system.......................................... 77 1.7.4 Radiator and expansion tank....................... 77 1.7.5 Cooling fan....................................... 78 1.7.7 Coolant........................................... 78 1.9 Control system, engine.................................. 82 1.9.1 Engine control unit............................... 82 1.11 Start/stop............................................. 83 1.11.1 Starter motor.................................... 83 1.11.2 Stopping device.................................. 83 2 Transmission...................................................... 85 2 Transmission.................................................. 87 2.1 Controls and instruments................................ 93 2.1.1 Gear selector and multi-function lever............ 93 2.2 Torque converter/Clutch system.......................... 94 2.2.1 Flex plates....................................... 94 2.6 Lubrication system...................................... 97 2.6.3 Oil cooler........................................ 99 2.7 Cooling system..........................................101 2.7.3 Oil cooler........................................101 2.8 Control system, transmission............................102 2.8.1 Transmission control unit.........................102 2.8.2 NO (normally open) switch, disengagement..........102 2.8.3 Transmission cable harness........................102 3 Power transmission................................................103 3 Power transmission............................................105 3.2 Propeller shaft.........................................105 3.3 Drive axle..............................................106 4 Brakes............................................................111 4 Brakes........................................................113 4.1 Controls and instruments................................113 4.1.1 Brake pedal.......................................113 4.3 Power-assisted brake system.............................115 4.3.1 Hydraulic oil pump................................116 4.3.2 Brake oil filter..................................116 4.3.3 Accumulator charging valve........................117 4.3.4 Accumulator.......................................120 4.3.5 Brake valve.......................................124 4.3.6 Drive axle block..................................128 4.3.7 Break contact (opening switch) brake pressure.....129 4.3.8 Make-contact (closing switch) brake lights........131 4.3.9 Wheel brakes......................................134 4.3.10 Pipes and hoses..................................136 4.3.12 Valve block brake system.........................137 4.5 Parking brake system....................................139 4.5.1 Hydraulic oil pump................................140 4.5.2 Hydraulic oil filter..............................140 4.5.3 Solenoid valve parking brake......................141 4.5.4 Parking brake unit................................142 4.5.5 Break contact (opening switch) parking brake......146 4.5.6 Pipes and hoses...................................146 4.5.7 Valve block brake system..........................146 5 Steering..........................................................147 5 Steering......................................................149 5.2 Power assisted system...................................149 5.2.1 Hydraulic oil pump................................149 5.2.2 Priority valve....................................150 5.2.3 Steering valve....................................153 5.2.4 Steering cylinder.................................155 5.2.5 Steering axle cradle..............................157 5.2.6 Link arm..........................................157 5.2.7 Wheel spindle.....................................158 5.2.8 Wheel hub.........................................158 5.2.13 Pipes and hoses..................................158 6 Suspension........................................................159 6 Suspension....................................................161 6.2 Suspension..............................................161 6.2.1 Steering axle cradle..............................162 6.2.2 Wheel spindle.....................................164 6.2.3 Wheel hub.........................................166 6.3 Tyres and rims..........................................171 6.3.1 Tyres.............................................173 6.3.2 Rim...............................................174 6.3.3 Nut, washer and clamp.............................175 7 Load handling.....................................................177 7 Load handling.................................................179 7.1 Controls and instruments................................180 7.1.1 Control levers....................................180 7.1.2 Switch, lock twistlock............................181 7.1.3 Switch, spreading 20\q-40\q.......................182 7.1.4 Switch, stop at 30\q..............................182 7.1.13 Switch, automatic spreading......................183 7.2 Lift and lower..........................................184 7.2.1 Hydraulic oil pump................................186 7.2.3 Pressure reducer..................................187 7.2.5 Control valve, lift and tilt......................190 7.2.7 Lift cylinder.....................................191 7.2.9 Mast..............................................192 7.2.10 Mast position sensor.............................201 7.2.11 Trolley..........................................202 7.2.13 Pipes and hoses..................................206 7.2.14 Accumulator lift.................................206 7.2.15 Hydraulic oil filter.............................206 7.4 Side shift..............................................207 7.4.1 Hydraulic oil pump................................208 7.4.2 Control valve, attachment.........................209 7.4.3 Side shift cylinder...............................213 7.4.5 Trolley...........................................213 7.4.7 Relief valve, attachment..........................215 7.4.8 Pipes and hoses...................................215 7.4.9 Lift, tilt and attachment control valve...........216 7.4.10 Hydraulic oil filter.............................216 7.5 Spreading (positioning).................................217 7.5.1 Hydraulic oil pump................................223 7.5.2 Control valve, attachment.........................224 7.5.3 Spreading cylinder................................225 7.5.4 Spreader beam.....................................225 7.5.5 Main beam, side lift attachment...................227 7.5.6 Position sensor, spreading........................232 7.5.7 Buzzer, automatic spread 20'-40'..................232 7.5.8 Pipes and hoses...................................232 7.5.9 Relief valve, attachment..........................232 7.5.10 Lift, tilt and attachment control valve..........232 7.5.11 Hydraulic oil filter.............................233 7.7 Tilt....................................................234 7.7.1 Hydraulic oil pump................................235 7.7.5 Control valve, lift and tilt......................236 7.7.6 Load retention valve..............................237 7.7.7 Tilt cylinder.....................................237 7.7.8 Mast..............................................238 7.7.9 Pipes and hoses...................................238 7.7.10 Hydraulic oil filter.............................238 7.8 Levelling...............................................239 7.9 Load carrier............................................240 7.9.1 Twistlocks........................................240 7.10 Other functions........................................251 7.10.1 Container counter................................251 8 Control system....................................................253 8 Control system................................................255 8.1 Controls and instruments................................256 8.1.10 Error code menu..................................256 8.2 Monitoring..............................................259 8.2.2 Bypass............................................259 8.2.3 Speed limitation..................................259 8.2.4 Service indicator.................................260 8.4 Diagnostics.............................................261 8.4.1 CAN/POWER.........................................263 8.4.2 LIGHTS............................................277 8.4.3 CAB...............................................289 8.4.4 CLIMATE...........................................297 8.4.5 HYD...............................................303 8.4.6 ENGINE............................................307 8.4.7 TRANSM............................................314 8.4.8 ELSERV............................................321 8.4.9 ATTACH............................................328 8.4.10 OLS..............................................341 8.4.11 EXTRA............................................341 8.5 Setup...................................................347 8.5.1 Initiation........................................347 8.5.2 Calibration.......................................364 9 Frame, body, cab and accessories..................................367 9 Frame, body, cab and accessories..............................369 9.1 Controls and instruments................................369 9.1.1 Gear selector and multi-function lever............374 9.1.22 Switch, direction indicators.....................375 9.2 Safety and emergency equipment..........................376 9.2.1 Control breaker...................................376 9.2.2 Seat belt.........................................376 9.2.3 Fire extinguisher.................................376 9.2.4 Seat buzzer.......................................376 9.3 Seat....................................................377 9.3.1 Seat cushion......................................380 9.3.2 Back rest cushion.................................381 9.3.3 Heating coil......................................382 9.3.4 Bumper............................................382 9.3.5 Air suspension....................................383 9.3.6 Compressor air-suspension seat....................383 9.3.7 Mechanical seat adjustment........................384 9.3.8 Passenger seat....................................384 9.3.9 Arm rest..........................................384 9.3.14 Sensor, operator-in-seat.........................385 9.4 Heating, ventilation and air conditioning...............387 9.4.1 Fresh air filter..................................394 9.4.2 Fresh air filter or recirculation damper..........395 9.4.3 Cabin fan.........................................398 9.4.4 Heat exchanger heat...............................401 9.4.5 Water valve.......................................404 9.4.6 Sensor, engine temperature........................404 9.4.7 Compressor........................................405 9.4.8 Condenser.........................................409 9.4.9 Moisture filter...................................411 9.4.10 Pressure switch..................................411 9.4.11 Expansion valve..................................412 9.4.12 Sensor, temperature refrigerant..................414 9.4.13 Heat exchanger, cooling..........................415 9.4.14 Air distributor..................................416 9.4.15 Defroster nozzles................................417 9.4.16 Sensor, temperature outlet fan...................418 9.4.17 Sensor cab temperature...........................419 9.4.18 Sensor, ambient temperature......................420 9.5 Wiper/washer system.....................................421 9.5.1 Wiper front.......................................421 9.5.2 Wiper roof........................................421 9.5.3 Wiper rear........................................421 9.5.4 Washer motor and reservoir........................421 9.5.5 Wiper motor front.................................422 9.5.6 Wiper motor roof..................................423 9.5.7 Wiper motor rear..................................424 9.6 Lighting system.........................................425 9.6.1 Headlights........................................429 9.6.2 Running lights....................................429 9.6.3 Tail lights.......................................429 9.6.4 Brake lights......................................429 9.6.5 Back-up lights....................................430 9.6.6 Direction indicators..............................430 9.6.7 Flashing hazard lights............................430 9.6.8 Revolving beacon..................................430 9.6.9 Working lights, mast..............................430 9.6.10 Working lights, cab..............................432 9.6.11 Interior lighting................................432 9.6.12 Working lights, attachment.......................433 9.6.14 Work lights, front wing..........................433 9.7 Signalling system.......................................434 9.7.1 Horn..............................................436 9.7.2 Flashing hazard lights............................436 9.7.3 Revolving beacon..................................437 9.7.4 Warning parking brake.............................437 9.7.5 Back-up alarm.....................................437 9.8 Entertainment and communication.........................438 9.9 Glass/windows/mirrors...................................439 9.9.1 Windscreen........................................440 9.9.2 Side window.......................................442 9.9.3 Roof window.......................................445 9.9.4 Rear window.......................................445 9.9.5 Rear view mirror..................................445 9.10 Cab structure and suspension...........................446 9.10.1 Cab frame........................................446 9.10.2 Doors............................................446 9.10.3 Cab substructure.................................446 9.11 Cab interior...........................................447 9.11.1 Instrument and control panels....................447 9.11.2 Interior fittings, plastic.......................448 9.11.3 Interior fittings, textile.......................448 9.11.4 Floor covering...................................448 9.11.5 Insulation.......................................448 9.11.7 Terminal console.................................449 9.11.8 Writing desk.....................................449 9.11.9 Reading-lamp.....................................449 9.12 Chassis................................................450 9.13 Body structure.........................................451 9.13.1 Wings............................................451 9.13.2 Hood engine compartment..........................451 9.13.3 Footsteps and hand rail..........................451 9.13.4 Counterweights...................................452 9.14 Central lubrication....................................453 9.14.1 Pump unit........................................455 9.14.2 Distribution block...............................456 9.14.3 Lines............................................456 9.15 Paint/coatings.........................................457 10 Common hydraulics................................................459 10 Common hydraulics............................................461 10.2 Safety valves..........................................461 10.2.1 Accumulator drain valve..........................461 10.2.2 Relief valve, attachment.........................461 10.2.3 Pressure limiting valve..........................462 10.2.4 Pipes and hoses..................................462 10.3 Tanks and accumulators.................................463 10.3.1 Hydraulic oil tank...............................463 10.3.2 Accumulator......................................463 10.3.4 Pipes and hoses..................................463 10.4 Pumps..................................................464 10.4.1 Gear pump with fixed displacement................464 10.4.3 Pipes and hoses..................................470 10.5 Hoses, pipes and valves................................471 10.5.1 Pipes and hoses..................................471 10.5.4 Main valve.......................................472 10.6 Temperature control, cleaning and hydraulic oil........476 10.6.2 Cooler hydraulic oil.............................478 10.6.3 Cooling fan......................................479 10.6.4 Sensor hydraulic oil temperature.................479 10.6.5 Bypass valve, cooler.............................481 10.6.6 Breather filter hydraulic oil tank...............482 10.6.7 Hydraulic oil filter.............................482 10.6.8 Hydraulic oil....................................484 10.6.9 Pipes and hoses..................................485 10.6.10 Fine filter hydraulic oil.......................485 10.7 Other..................................................487 10.7.1 Hydraulic cylinders..............................487 11 Common electrics.................................................497 11 Common electrics.............................................499 11.2 Electric protection....................................499 11.2.1 Battery disconnector.............................499 11.2.2 Fuses............................................499 11.2.3 Control breaker..................................499 11.3 Batteries..............................................500 11.3.1 Start battery....................................500 11.4 Alternator.............................................502 11.4.1 Alternator.......................................502 11.5 Distribution of electricity............................503 11.5.1 Voltage feed.....................................503 11.5.2 Electronic box...................................510 11.5.3 Control units....................................512 11.5.5 Cable harness....................................521 11.6 Communication..........................................530 11.6.1 CAN bus..........................................530 11.6.2 Redundant CAN bus................................532 11.6.3 CAN bus drive-train..............................534 11.6.4 Communication between PC and machine.............535 D Error codes.......................................................537 D Error codes...................................................539 1 Engine........................................................545 2 Transmission..................................................595 8 Control system................................................631 E Schematics........................................................649 E Schematics....................................................651 Common hydraulics..........................................651 Common electrics...........................................654 Wiring...................................................... 0 A49226.0100.............................................659 0 | WIRING,DCF370-,DCE300-..........................659 0.0_1 | Crossreference list.........................660 0.0_2 | Crossreference list.........................661 0.0_3 | Crossreference list.........................662 0.0_4 | Crossreference list.........................663 0.1_1 | Truth table opt.............................664 1.0_1 | Wiring drivetrain engine....................665 1.0_2A | Wiring engine TAD722.......................666 1.0_2B1 | Wiring engine Cummins QSM11...............667 1.0_2B2 | Wiring engine Cummins QSM11...............668 1.0_2C | Wiring engine 950,1240,1250................669 1.0_2D | Wiring engine TAD760.......................670 1.0_2E1 | Wiring engine QSB6,7......................671 1.0_2E2 | Wiring engine QSB6,7......................672 1.0_2F | Wiring engine D7,D13.......................673 2.0_1 | Wiring drive train gearbox..................674 2.0_2A1 | Wiring gearbox TE32.......................675 2.0_2A2 | Wiring gearbox TE32.......................676 2.0_2A3 | Wiring gearbox TE32.......................677 2.0_2B1 | Wiring gearbox TE17.......................678 2.0_2B2 | Wiring gearbox TE17.......................679 2.0_2B3 | Wiring gearbox TE17.......................680 2.0_2C1 | Wiring Dana TE 32FF.......................681 2.0_2C2 | Wiring Dana TE 32FF.......................682 2.0_2C3 | Wiring Dana TE 32FF.......................683 4.0_1 | Wiring brake system.........................684 4.8_1 | Wiring cooling brake oil....................685 5.2_1 | Wiring lever/micro wheel....................686 5.2_2 | Wiring lever/micro wheel....................687 7.0_1 | Wiring el. servo levers.....................688 7.0_2 | Wiring el. servo joystick...................689 7.0_4 | Wiring toplift frame........................690 7.0_5 | Wiring toplift frame........................691 7.0_7 | Wiring lift height..........................692 7.2_1 | Wiring lift/lower el. servo.................693 7.2_2 | Wiring free lift sensors....................694 7.2_3 | Wiring free lift sensors....................695 7.2_6 | Wiring control valves mast..................696 7.3_1 | Wiring projection gantry....................697 7.4_1 | Wiring Sideshift el. servo..................698 7.4_2 | Wiring sideshift gantry.....................699 7.5_1 | Wiring 20-40, 30-35 stop....................700 7.5_2 | Wiring spreading gantry.....................701 7.5_3 | Wiring 20-40 opt............................702 7.7_1 | Wiring tilt el. servo.......................703 7.7_2 | Wiring tilt indicator.......................704 7.8_1 | Wiring levelling gantry.....................705 7.9_1 | Wiring twistlock............................706 7.9_2 | Wiring sensors gantry.......................707 7.9_3 | Wiring attachment Avesta....................708 7.9_4 | Wiring Over Height..........................709 7.10_1 | Wiring 5th function el. servo..............710 7.10_2 | Wiring option gantry.......................711 8.2_1 | Wiring override.............................712 8.2_2 | Wiring overloading system...................713 8.2_3 | Wiring sensor mast OLS......................714 8.2_4 | Wiring RMI..................................715 9.0_1 | Wiring std. opt.............................716 9.1_1 | Wiring option...............................717 9.1_2 | Wiring hour meter...........................718 9.3_1 | Wiring seat heater..........................719 9.3_2 | Wiring aircushioned seat....................720 9.3_3 | Wiring turnable drivers seat................721 9.3_4 | Wiring turnable drivers seat................722 9.3_5 | Wiring turnable drivers seat................723 9.3_6 | Wiring turnable drivers seat................724 9.3_7 | Wiring turnable drivers seat................725 9.4_1 | Wiring climate control......................726 9.4_2 | Wiring climate control......................727 9.4_3 | Wiring condensor chassis....................728 9.5_1 | Wiring wiper function.......................729 9.6_1 | Wiring work lights 20-40....................730 9.6_2 | Wiring work lights carriage.................731 9.6_3 | Wiring work lights mast.....................732 9.6_4 | Wiring lights...............................733 9.6_5 | Wiring lights...............................734 9.6_6 | Wiring lights...............................735 9.6_7 | Wiring light director & hazard..............736 9.6_8 | Wiring interior lights......................737 9.6_9 | Wiring work lights option...................738 9.6_10 | Wiring work lights option..................739 9.6_11 | Wiring step in light.......................740 9.6_12 | Wiring work lights carriage opt............741 9.6_13 | Wiring work lights option fenders..........742 9.6_14 | Wiring work lights option carriage.........743 9.7_1 | Wiring alarm, buzzer and horn...............744 9.7_2 | Wiring reversing alarm......................745 9.7_3 | Wiring compressor horn......................746 9.7_4 | Wiring horn servo panel.....................747 9.8_1 | Wiring radio................................748 9.8_2 | Wiring printer..............................749 9.9_1 | Wiring heating mirrors......................750 9.9_2 | Wiring cameraWiring camera..................751 9.10_1 | Wiring cab tilt/sliding cab................752 9.14_1 | Wiring central lubrication.................753 10.4_1 | Wiring interruption hydr. pump.............754 10.6_1 | Wiring cooling hydraulic oil...............755 11.5_1 | Wiring power...............................756 11.5_2 | Wiring power...............................757 11.5_3 | Wiring power...............................758 11.5_4 | Wiring power...............................759 11.5_5 | Wiring power...............................760 11.5_6 | Wiring power operating switch..............761 11.5_7 | Wiring 24/12V..............................762 11.5_8 | Wiring 24V contact.........................763 11.5_9 | Wiring option base power...................764 11.5_10 | Wiring option base........................765 11.5_11 | Wiring option base........................766 11.6_1 | Wiring CANBUS base.........................767 11.6_2A | Wiring CANBUS KDU opt. chassi.............768 11.6_2B | Wiring CANBUS KDU opt. attachment.........769 11.6_2C | Wiring CANBUS KDU opt. chassi + attach....770 A50400.0100.............................................771 0.0_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....771 7.4_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....772 7.5_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....773 7.5_2 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....774 7.5_3 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....775 7.8_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....776 7.9_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....777 7.9_2 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....778 7.9_3A | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....779 7.9_3B | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....780 7.9_4 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....781 7.9_5A | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....782 7.9_5B | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....783 9.6_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E.....784 9.14_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....785 11.5_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....786 11.5_2 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....787 11.6_1 | WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E....788 A59539.0100.............................................789 0...................................................789 1.0_1A1.............................................790 1.0_1A2.............................................791 1.0_1B..............................................792 2.0_1A1.............................................793 2.0_1A2.............................................794 List of Components..........................................795 F Technical data....................................................813 F Technical data................................................815 G Terminology and index.............................................829 G Terminology and index.........................................831 Terminology.................................................831 Index.......................................................833
DESCRIPTION:
Kalmar Empty Container Handler 8-9T DCT80-90 Workshop Manual – PDF DOWNLOAD
About the Workshop Manual:
General:
- Thank you for choosing Cargotec as your machine supplier. We hope
that we’ll meet your expectations.
Conditions:
- The instructions are based on the use of generally available standard
tools. All lifting devices, for example, slings, straps, ratchet blocks,
etc., must meet governing national standards and regulations for lifting
devices. - Cargotec will not accept any responsibility for modifications performed
without permission from Cargotec or if other lifting devices, tools or
work methods are used other than those described in this manual.
About the machine version:
- The information in this publication corresponds to the machine’s design
and appearance at the time of delivery from Cargotec. Due to customizations,
there may be variations and/or deviations. - Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in this manual are valid at
the time of publication.
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