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)

VDCF03.01GB
Workshop Manual DCF 90-100
A Foreword – Reading instructions 9
Symbol explanation function descriptions
The following symbols are used in function descriptions, the symbols
are based on standard symbols used in wiring and hydraulic diagrams.
1. Electric control signal
2. Electric force
3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7. Hydraulic oil pump with fixed displacement
8. Electrical motor
9. Accumulator
10. Disc brake
11. Filter
12. Radiator
13. Bulb
14. Control system, two control units with CAN bus
15. Restriction
16. Adjustable restriction
17. Inductive position sensor
18. Electrically controlled servo valve
19. Thermal bypass valve
20. Temperature-controlled switch
21. Temperature sensor
22. Pressure sensor
23. Pressure-controlled switch
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
28. Shuttle valve
29. Non-return valve
˚C
˚C
Pa
M
Pa
D790-1
D797-F
˚C
12
34
56
78
910
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25
26 27
28 29
000523

VDCF03.01GB Workshop Manual DCF 90-100
10 A Foreword – About the documentation
About the documentation
page– Documentation sections
The documentation to the machine comprises the following sections:
Operator's manual
The Operator's manual is supplied with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied with the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual.
• Supplier documentation for engine, transmission and drive axle.
page– Ordering of documentation
Documentation is ordered from the dealer.
Always specify the publication number when ordering.

VDCF03.01GB
Workshop Manual DCF 90-100
A Foreword – Feedback 11
Feedback
page– Form for copying
Kalmar Industries’ ambition is that you who work with maintenance of
Kalmar machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thank you for
your participation!
To: Kalmar Industries AB
Product Support
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: [phone]
From:
Company / Sender: ..........................................................................................................................................
Telephone: ..........................................................................................................................................................
E-mail: .................................................................................................................................................................
Date: .................................... - .................. - ..................
Manual
informa-
tion Name / Publication number: .............................................................................................................................
Section / page number: ......................................................................................................................................
Sugges-
tions,
views, re-
marks,
etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................

VDCF03.01GB Workshop Manual DCF 90-100
12 A Foreword – Feedback

VDCF03.01GB
Workshop Manual DCF 90-100
BSafety 1
B Safety
mm mm mm mm mm mm
Table of Contents B Safety
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurizing ................................................... 5
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 8
Working under machine .................................................................................... 9
Lifting heavy components ................................................................................. 9
Vibrations ........................................................................................................ 10
Noise ............................................................................................................... 10
Solvents .......................................................................................................... 11
Fire and explosion risks ................................................................................... 11
Fluid or gas under pressure ............................................................................ 12
Coolant ............................................................................................................ 13
Refrigerant ...................................................................................................... 14
Air pollution ..................................................................................................... 14
Tensioned springs ........................................................................................... 15
Electric motors ................................................................................................. 15
Rotating components and tools ....................................................................... 16
Tyre and rim system ........................................................................................ 17
Lifting equipment ............................................................................................. 17
Environment ............................................................................................. 18
General ........................................................................................................... 18

VDCF03.01GB Workshop Manual DCF 90-100
2 B Safety

VDCF03.01GB
Workshop Manual DCF 90-100
B Safety – Safety 3
mm mm mm mm mm mm Safety
General safety information
page– Safety concerns everyone!
The safety information concerns everyone who works with the ma-
chine! 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 ma-
chine 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 mainte-
nance manual and operator’s manual.
page– A near accident is a warning!
A near-accident is an unexpected event where neither persons, ma-
chine or property are injured or damaged. However, a near-accident
indicates that there is an injury risk and actions must be taken to avoid
the risk of injuries.

VDCF03.01GB Workshop Manual DCF 90-100
4 B Safety – Safety instructions
Safety instructions
page– General
Read, consider and follow the safety instructions below before starting
to work in the machine:
•Service position page 4
•Hydraulic and brake systems, depressurizing page 5
•Oils page 6
•Fuel system page 7
•Clothing, etc. page 8
•Several mechanics on the same machine page 8
•Working under machine page 9
•Lifting heavy components page 9
•Vibrations page 10
•Noise page 10
•Solvents page 11
•Fire and explosion risks page 11
•Fluid or gas under pressure page 12
•Coolant page 13
•Refrigerant page 14
•Air pollution page 14
•Tensioned springs page 15
•Electric motors page 15
•Rotating components and tools page 16
•Tyre and rim system page 17
•Lifting equipment page 17
page– Service position
Machine with lifting carriage and attachment in totally
lowered position
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position means:
• Machine parked, that is, parking brake applied.
• Lifting carriage and attachment in totally lowered position.
• Engine off.
• Main electric power off (with battery disconnect switch).
009797

VDCF03.01GB
Workshop Manual DCF 90-100
B Safety – Safety instructions 5
page– Hydraulic and brake systems, depressurizing
1 Machine in service position, see Service position page 4.
2 Depressurise the hydraulic system by draining servo pressure
from the accumulator.
Turn the main current on, turn the starter key to position I and ac-
tivate the load handling functions several times.
3 Turn the start key to position 0 and turn off the main electric pow-
er.
4 Depressurise the brake system by opening the drain valve on the
accumulator charging valve.
NOTE
Keep the drain valve open as long as work is in progress.
When closing the drain valve, check that it is fully closed and
tighten the lock ring.
009798
005648

VDCF03.01GB Workshop Manual DCF 90-100
6 B Safety – Safety instructions
page– Oils
The following safety instructions shall be followed for work when hand-
ling oils.
WARNING
Warm and pressurized oil.
Always depressurise hydraulic and brake systems
completely before starting to work in the systems. Hy-
draulic and brake systems are pressurised and the oil
may cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Warm oil can cause burn injuries, rashes and irrita-
tion! The oil may also be corrosive to mucous mem-
branes in, e.g., the eyes, skin and throat.
IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall al-
ways be handled by an authorized company.