Kalmar DCF 90-100 Instruction manual

AForeword
BSafety
CPreventive maintenance
0Complete machine
1Engine
2 Transmission
3Driveline/axle
4Brakes
5Steering
6Suspension
7Load handling
8Control system
9Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
DError codes
ESchematics
FTechnical data
GTerminologyand Index
Workshop manual

VDCF03.01GB
Workshop Manual DCF 90-100
AForeword 1
A Foreword
mm mm mm mm mm mm
Table of Contents A Foreword
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
Workshop manual contents ............................................................................... 3
References between different information types ............................................... 4
Function group breakdown ................................................................................ 5
Conditions ......................................................................................................... 5
Storage .............................................................................................................. 5
About the machine version ................................................................................ 5
Copyright ........................................................................................................... 5
Reading instructions ................................................................................... 6
Warning information .......................................................................................... 6
Important information ........................................................................................ 6
Read the operator's manual/maintenance manual ............................................ 6
Optional equipment ........................................................................................... 6
Function descriptions ........................................................................................ 7
About the documentation ......................................................................... 10
Documentation sections .................................................................................. 10
Ordering of documentation .............................................................................. 10
Feedback .................................................................................................. 11
Form for copying ............................................................................................. 11

VDCF03.01GB Workshop Manual DCF 90-100
2 A Foreword

VDCF03.01GB
Workshop Manual DCF 90-100
A Foreword – Foreword 3
mm mm mm mm mm mm Foreword
About the Workshop Manual
page– General
Thank you for choosing Kalmar Industries as your machine supplier.
We hope that we'll meet your expectations.
page– Workshop manual contents
The workshop manual contains information for corrective mainte-
nance (replacement of components) and serves to supplement the
maintenance manual. The workshop manual is accompanied by sup-
plier documentation for engine, transmission and drive axle. Wherever
possible, the workshop manual makes refers to the maintenance man-
ual and supplier documentation to avoid double information.
The workshop manual is divided into the following sections.
A Foreword General information about the workshop manual's purpose, contents and reading in-
structions as well as survey for feedback of views and any inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance Reference to maintenance manual: Preventive maintenance.
0 Complete machine
Technical description, comprehensive function descriptions and a description of the
function of components included in the machine, divided into function groups.
The components used for each function are described under each subfunction. Con-
sequently, common components are described in several places, but in general un-
der the first function to use the component.
Together with the general description is a detailed description of what is unique
about the specific subfunction. The next subfunction to use the same component
only has a description what is unique for the new function.
Work instructions for corrective maintenance (replacement of components).
1 Engine
2 Transmission
3 Driveline/axle
4 Brakes
5Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and acces-
sories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code information.
E Schematics Wiring and hydraulic diagrams.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanation of terms and abbreviations that
can appear in the sections, index for headings in the sections.

VDCF03.01GB Workshop Manual DCF 90-100
4 A Foreword – About the Workshop Manual
page– References between different information types
The maintenance manual and workshop manual are mainly divided
into function groups, see Workshop manual contents page 3. Certain
parts are broken out as separate parts to increase usability, e.g.,
"Technical data".
The basic rule of searching for information is to use function groups to
find different types of information regarding the function or component
in question. As a complement to this, there are references according
to the below.
• From Function description to Component description, to enable
fast finding of more information about the different components
that create a function.
• From Function description to Hydraulic diagram, to enable fast
finding of the right hydraulic diagram for the function in question.
• From Component description or Function description to Diagnos-
tics, to enable fast finding of the right diagnostic menu that can be
used to check the component (only applies to electrical compo-
nents).
• From Diagnostics to Wiring diagrams. to enable fast finding of the
right circuit diagram for further troubleshooting.
• From Diagnostics to Component description or Function descrip-
tion. To enable fast finding of more information about the compo-
nent's appearance and position when troubleshooting.
• From Error codes to Diagnostics, to enable fast finding of the right
diagnostic menu to troubleshoot component or function in ques-
tion.
• From Error codes to Function description or Component descrip-
tion, to enable fast finding of more information about components
or function.
Function descriptions
(Technical description)
Hydraulic diagrams
(Section E)
Component descriptions
(Technical description, usually in Workshop manual)
Error codes
(Section D)
Diagnostics
(Group 8.4)
Wiring diagrams
(Section E)

VDCF03.01GB
Workshop Manual DCF 90-100
A Foreword – About the Workshop Manual 5
page– Function group breakdown
Breakdown into function groups is common for all machines from Ka-
lmar Industries, down to two-digit heading level (e.g., 4.3 Power-as-
sisted brake system). Machine-unique adaptations of function groups
are done at the third and fourth group levels (e.g., 4.3.9 Wheel brake
resp. 4.3.9.1 Disc assembly).
This results in certain headings (function groups) being omitted in the
documentation for certain machines since the machine lacks that par-
ticular function. This means that there may be gaps in the function
groups' numbering (e.g., the three-digit heading level 4.8.7 Oil cooler
may be included for certain machines, but may be missing for other
machines).
References between sections within the same manual are indicated
using section and group number, e.g., "see section 4 Brakes, group
4.3.9 Wheel brake ". A reference within the same section is indicated
with page number, e.g., "see Sensor fuel level, description page 24 ".
page– Conditions
The instructions are based on the use of generally available standard
tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet governing national standards and regulations for lifting devices.
Kalmar Industries will not accept any responsibility for modifications
performed without permission from Kalmar Industries or if other lifting
devices, tools or work methods are used other than those described in
this manual.
page– Storage
NOTE
The workshop manual should be accessible to service personnel.
page– About the machine version
The information in this publication corresponds to the machine's de-
sign and appearance at the time of delivery from Kalmar Industries.
Due to customizations, there may be variations and/or deviations.
Kalmar Industries 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.
page– Copyright
Kalmar Industries AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Kalmar Industries AB.
Duplication by any means such as copying, printing, etc., is prohibited.

VDCF03.01GB Workshop Manual DCF 90-100
6 A Foreword – Reading instructions
Reading instructions
page– Warning information
Warnings inform on potential dangers which can, if the warnings are
not heeded, result in personal injury or product damage.
page– Important information
Important information marked with NOTE facilitates the work process,
operation/handling or increases understanding of the information.
NOTE
Information that is important without being safety related.
page– Read the operator's manual/maintenance
manual
Read the operator’s manual/maintenance manual
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the operator’s/maintenance manual.
page– Optional equipment
Indicates optional equipment
The symbol to the left is used in the manual to indicate that a function
or component is optional equipment. Detailed information on how the
machine is equipped is presented by the machine card enclosed with
the spare parts catalogue.
DANGER
Situation that may result in serious personal injury,
possible death, if the instruction is not followed.
WARNING
Situation that may result in serious personal injury if
the instruction is not followed.
CAUTION
Situation that may result in damage to the product if
the instruction is not followed.
000262
000264

VDCF03.01GB
Workshop Manual DCF 90-100
A Foreword – Reading instructions 7
page– Function descriptions
Function descriptions are schematic overviews that describe how a
function works as well as which components and signals work togeth-
er.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions are fulfilled for the function to be activated. In these cases, the
conditions are listed above the illustration.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.
Example of function description
010689
1
2
3
4
5
6
7
8
9
10

VDCF03.01GB Workshop Manual DCF 90-100
8 A Foreword – Reading instructions
1. Flag diagnostics, indicates that the signal can be checked with a
diagnostic test; see group 8.4 Diagnostics
2. Hydraulic force (solid double line)
3. Illustration of function, (lift and lower)
4. Reference to description of component
5. Signal description, reference value for signal out from component
6. Description of component's function
7. Position number, reference to position in illustration
8. Position number in illustration, reference to row in table
9. Flag pressure check connection (Check point), indicates that
there is pressure check connection for checking pressure signal
10. Electric power (solid single line)