Академический Документы
Профессиональный Документы
Культура Документы
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance
manual 2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
A Foreword
Foreword......................................................................................................... 3
About the Maintenance Manual .................................................................. 3
General ............................................................................................................. 3
Conditions ......................................................................................................... 3
Storage .............................................................................................................. 3
About the machine version ................................................................................ 3
Copyright ........................................................................................................... 3
Reading instructions ................................................................................... 4
Warning information .......................................................................................... 4
Important information ........................................................................................ 4
Read operator's manual .................................................................................... 4
Read maintenance manual ............................................................................... 4
Maintenance manual's content .......................................................................... 5
Function group structure ................................................................................... 6
Product alternatives and optional equipment .................................................... 7
Machine card ..................................................................................................... 8
Function descriptions ........................................................................................ 9
About the documentation ......................................................................... 12
Documentation sections .................................................................................. 12
Ordering of documentation .............................................................................. 12
Feedback .................................................................................................. 13
Forms for copying ............................................................................................ 13
Foreword
mm mm mm mm mm mm
Conditions
page
–
Storage
page
–
NOTE
The maintenance manual shall be accessible to service person-
nel.
Copyright
page
–
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.
Reading instructions
Warning information
page
–
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.
Important information
page
–
NOTE
Information that is important without being safety related.
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the operator’s manual.
000262
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the maintenance manual.
001128
A Foreword General information about the maintenance manual's purpose, content and read-
ing instructions as well as survey for feedback of views and eventual inaccuracies.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/axle
4 Brakes
Technical description, description of the machine's functions with schematic
5 Steering
drawings and explanatory texts for the included components.
6 Suspension Overviews with the components' position on the machine.
7 Load handling Work instructions for preventive maintenance.
8 Control system Work instructions for checking and adjusting.
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information please refer to Operator’s manual and
Workshop manual
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanations of terms and abbreviations
that may appear in the manual, index for headings in the manual.
Product alternatives
Product alternatives are such options that exclude certain standard
equipment (e.g., engine alternative).
Similar information for different product alternatives are described in
separate sections following each other in the same function group. To
show that there are different alternatives, the added text "Product al-
ternative" is used in the heading, together with a simple description of
which alternative is described, e.g., "(Product alternative Air condition-
ing ECC)".
Optional equipment
000264
Machine card
page
–
NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.
The machine card indicates of which drawings the machine consists,
in many cases these can be connected to options and product alterna-
tives. For more information about handling of product alternatives and
optional equipment, see Product alternatives and optional equipment
page 7. The machine card is delivered with the parts catalogue and
shall be kept in the cab.
The machine card is divided in the same functions groups as the parts
catalogue, maintenance and Workshop manual. For practical reasons,
the machine card uses only the first and second level in the function
group register. The function groups are written in groups of four char-
acters, e.g. group 0107 matches group 1.7 Cooling system in the man-
ual.
For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.
If the information on the machine card does not help, contact Kalmar
Industries AB.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.
Function descriptions
page
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6
13
5
1
3
2
008070
13 14 14. Control and monitoring system, two control units with CAN-bus
D797-F 15. Restriction
16. Adjustable restriction
15 16
17. Inductive position sensor
17 18 18. Electrically controlled servo valve
19. Thermal by-pass valve
19 ˚C 20 ˚C
20. Temperature-controlled switch
˚C Pa 21. Temperature sensor
21 22
22. Pressure sensor
23 Pa 24 23. Pressure-controlled switch
24. Hydraulic cylinder
25 25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
26 27
28. Shuttle valve
29. Non-return valve
28 29
007991
000523
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
There are Supplementary documentation that can be ordered for the
machine.
• Workshop manual.
• Supplier’s documentation for e.g. engine, transmission and drive
axle etc.
Ordering of documentation
page
–
Feedback
Forms for copying
page
–
From:
Company / Sender: ..........................................................................................................................................
Telephone: ...........................................................................................................................................................
E-mail: .................................................................................................................................................................
Manual
informa- Name / Publication number: .............................................................................................................................
tion
Sugges-
tions, .............................................................................................................................................................................
views,
notes etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
B Safety
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near-accident is a warning signal! .................................................................. 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic system, depressurizing ...................................................................... 5
Oils .................................................................................................................... 5
Fuel system ....................................................................................................... 6
Clothing etc. ...................................................................................................... 7
Several mechanics on the same machine ......................................................... 8
Working under machine .................................................................................... 8
Lifting heavy components ................................................................................. 9
Vibrations ........................................................................................................ 10
Noise ............................................................................................................... 10
Solvents .......................................................................................................... 10
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 system ..................................................................................................... 17
Lifting equipment ............................................................................................. 17
Environment ............................................................................................. 18
General ........................................................................................................... 18
Safety
mm mm mm mm mm mm
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.
Safety instructions
General
page
–
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position page 4
• Hydraulic system, depressurizing page 5
• Oils page 5
• Fuel system page 6
• Clothing etc. page 7
• Several mechanics on the same machine page 8
• Working under machine page 8
• Lifting heavy components page 9
• Vibrations page 10
• Noise page 10
• Solvents page 10
• 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 system page 17
• Lifting equipment page 17
Service position
page
–
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position entails:
• The machine is parked, i.e. parking brake applied.
• Forks and lifting carriage in totally lowered position.
• The engine is switched off.
• The main circuit is disconnected (using the battery disconnect
switch).
007945
DANGER
Fatal danger!
NOTE
Keep the drain valve open as long as work is in progress.
Oils
page
–
The following safety instructions shall be followed for work when han-
dling oils.
WARNING
Warm and pressurised oil.
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.
Fuel system
page
–
The following safety instructions shall be followed for work when han-
dling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
WARNING
Use protective gloves and protective goggles. If a
component is to be disconnected, hold a rag over the
connection as protection and to collect fuel. The en-
gine's fuel system operates at very high pressure.
The pressure is so high that the jet can injure the skin,
resulting in severe injuries. Risk of personal injuries.
CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine stop in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.
IMPORTANT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Clothing etc.
page
–
WARNING
Be extra careful if several mechanics work on the
same vehicle, so that unintentional movements do
not injury another person. Communicate so that eve-
ryone knows where all are and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc. may result in
components on the other side moving and causing damage/injury.
Movements performed from the operator's station, e.g., movement of
lifting equipment, may cause severe personal injuries.
Safety actions
• Make sure that the machine's lifting equipment is completely low-
ered or secured in another way.
• Move battery disconnector to position zero, remove the key.
• Be aware of the risks when several persons work around the ve-
hicle.
• Make your co-workers aware of what you’re working with.
• Do not work with drive wheels on the machine's both sides at the
same time.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or acci-
dentally be lowered due to malfunctions or incorrect use.
Safety actions
Use axle stands and supports that stands steadily.
Lifting tools should be inspected and type approved for use.
WARNING
Careless handling of heavy components can lead to
serious personal injury and material damage.
Risks
Unsuitable lift slings, straps, etc. may break or slip.
The centre of gravity (balance point) of the component can change
during the course of the work, and the component may then make un-
expected movements which may cause severe personal injuries and
material damage.
A component lifted with lifting equipment can start to turn if the equilib-
rium is upset.
A component lifted using an overhead crane may start to swing back
and forth, which can cause severe crushing injuries or material dam-
age.
Safety precautions
Lift using a lifting device. Use lifting tools or equipment, especially
when such equipment is available for specific work operations. See
the workshop manual for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
• Wear gloves. They're good protection against minor crushing in-
juries and cuts to fingers.
• Always use protective shoes.
Vibrations
page
–
In case of long-term use of vibrating tools, for example, impact nut run-
ners or grinders, injuries may be sustained as vibrations can be trans-
mitted from tools to hands. Especially when fingers are cold.
Safety actions
Use heavy gloves to protect against cold and somewhat against vibra-
tions.
Switch between work duties to give the body time to rest.
Vary work position and grip so that the body is not stressed in only one
position by the vibrations.
Noise
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High tones (high frequencies) are more damaging than low
tones at the same sound level. Impact noise can also be hazardous,
e.g. hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it is tested and protects against
the noise level in question.
Limit noise with noise-absorbing dividers, for example, noise-absorb-
ing materials in roof and on walls.
Solvents
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapors that can cause dizzi-
ness, headaches and nausea.They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent comes into direct contact with the skin, this may cause
drying and cracking.Risk for skin allergies increases. Solvents may
also cause injury if they penetrate through the skin and are absorbed
by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depressions,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause can-
cer.
Safety precautions
Avoid inhaling solvent fumes by providing good ventilation, or wearing
a fresh-air mask or respiratory device with a suitable filter for the toxic
gases.
Never leave a solvent container without tight-sealing lid.
Use solvents with low content of aromatic substances. This reduces
the risk of injuries.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.
Risks
Examples of causes of ignition include welding, cutting, smoking,
sparks produced by grinding, inflammable materials coming into con-
tact with hot machine parts, the generation of heat in rags saturated
with oil or paint (linseed oil) and oxygen.Oxygen cylinders, lines and
valves must be kept free from oil and grease.
Fumes from gasoline, for example, are heavier than air and can thus
“run down” a sloping grade, or down into a grease pit, where welding
flames, grinding sparks or a burning cigarette can cause an explosion.
Evaporated gasoline has a very powerful explosive force.
Special cases
Diesel fuel oil with an additive of petrol has a reduced flash point. Ex-
plosion risk even at room temperature. The explosion risk due to
warmed diesel fuel oil is greater than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near the machine. If diesel or other oils have leaked out
and have been absorbed by rags, absorbing agent, paper or other po-
rous material, glowing welding sparks can cause ignition and an explo-
sive spread of fire.
When a battery is being charged, the battery electrolyte water is divid-
ed into oxygen and hydrogen gas. This mixture is very explosive. The
risk of explosion is especially high when a booster battery or a rapid-
charge unit is used, as these increase the risk of sparks.
The machines nowadays contain a lot of electronic equipment. During
welding work, the control units must be disconnected and current
turned off using the battery disconnect switch. Otherwise, strong weld-
ing currents can short-circuit the electronics, destroy expensive equip-
ment, and may also cause an explosion or fire.
Welding work must never be carried out on painted surfaces (remove
paint by blasting at least 10 cm around the welding or cutting point.)
Use gloves, breathing protection and protective safety glasses. Also,
welding work must never take place near plastic or rubber materials
without first protecting them from the heat. Paints, plastics and rubber
generate various substances when heated that may be hazardous to
health. Be careful with machines that have been exposed to intense
heat or a fire.
Safety precautions
Store hazardous substance in approved and sealed container.
Make sure that there is no ignition source near flammable or explosive
substances.
Make sure that ventilation is adequate or there is an air extraction unit
when handling flammable substances.
High-pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
A gas cylinder subjected to careless handling can explode, for exam-
ple, if it falls onto a hard surface. Gas can stream out through dam-
aged valves.
Risks
There are injury risks in connection with work on:
• Hydraulic system (for example, working hydraulics and brake sys-
tem).
• Fuel system.
• Tyre replacement.
• Air conditioning.
Safety precautions
• Use safety glasses and protective gloves.
• Never work in on a pressurized system.
• Never adjust a pressure limiting valve to a higher pressure than
recommended by the manufacturer.
• A hydraulic hose that swells, for example, at a connection, is
about to rupture. Replace it as soon as possible! Check connec-
tions thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulators must first be punctured before
they are deposited as waste (to avoid risk of explosion). Carefully
drill a hole with 3 mm diameter after depressurizing.
• Never use your hands directly to detect a leak.A fine high-pres-
sure stream from a hydraulic hose can easily penetrate a hand
and causes very severe injuries.
Coolant
page
–
Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• Open the filler cap first, to release the excess pressure. Open
carefully.Hot steam and coolant can stream out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
page
–
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Contact the importer for further information.
Safety actions
• Use special instructions and equipment for refrigerant according
to the Workshop manual when working on the air conditioning
system. Special certification and authorization is often required of
the person who may do the work. (Note national legislation and lo-
cal regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
page
–
Air pollution is the impurities in the air around us and which are regard-
ed as hazardous to health. Certain pollution is more prominent in cer-
tain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
• Carbon monoxide (fumes) is present in exhaust fumes. Odor-
less and therefore especially dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanized or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulfuric acid mist is corrosive and injures the respiratory tracts. (Gen-
erated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or may be
present in aerosols) when cutting, grinding or welding. Can irritate mu-
cous membranes producing symptoms similar to asthma and impair-
ing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are gen-
erated.
• Use suitable gloves and breathing protection when there’s a risk
of oil mist. Make sure that protective gear is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eye-wash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect an air extractor to the exhaust pipe so that the exhaust
fumes are removed from the workshop.
Tensioned springs
page
–
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
page
–
Safety actions
Always turn off the battery disconnector when working on electric mo-
tors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before start-
ing any work on the machine.
Risks
Rotating components, for example, fans or shafts, can cause severe
injuries if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in the
machine.
Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewelry from hands, arms and
neck.
Tyre system
page
–
DANGER
Tyres should be regarded as pressurized containers.
They constitute fatal danger if handled incorrectly.
Risks
Dismantling wheels: Tyres, rims or lock rings can be thrown.
Inflating wheels: Tyres, rims and lock rings can be thrown.
Safety actions
• Deflate the tyres before starting to work on the wheel.
• Check that wheels, rims and lock rings aren’t damaged. Never re-
pair damaged rims or lock rings.
• Wheels must be inflated on the machine or in a protective device
which is designed and dimensioned to withstand or divert a pres-
sure wave from an exploding tyre, and to catch the pieces which
are thrown out.
• Use protective screen and safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the lifting equip-
ment in particular, the greatest caution must be exercised with respect
to securing the mast and carriage.
Always make a habit of lowering the carriage to its lowest position be-
fore working on the machine.
Risks
If the lifting equipment on the machine is not lowered or secured, there
is a pinch risk.
The pinch risk is much greater when the pressure in the hydraulic sys-
tem is being released, see Hydraulic system, depressurizing page 5.
Safety actions
Do not start work before the carriage has been completely lowered. If
the nature of the work requires the carriage to be raised then this must
be secured in some way.
Environment
General
page
–
Recycling
Carefully considered recycling of the machine is the basis for ending
the life cycle and being able to utilise the material for re-use in new
products. Our estimates show that more than 90% of the weight of the
machine can be re-used
C Preventive maintenance
Preventive maintenance
mm mm mm mm mm mm
CAUTION
The warranty is not valid if service intervals are not
followed.
instructions
1 For new machine it is very important to check-tighten the wheel
nuts during the first work week, until they are securely tightened.
This shall be performed at an interval of 4–5 operating hours (up
to approx. 40–50 operating hours).
2 For new machine, checking actions shall be performed after 50
hours of operation, see 50h-check page 5.
Note completed 50h check in the service log, see Check and
service log page 4.
3 Service at regular intervals shall be performed according to serv-
ice schedule, see Service schedule page 7. The service schedule
shall be followed to ensure the machine’s high operating reliabil-
ity.
Note completed service in the service log, see Check and service
log page 4.
Model:
Serial number:
Completed maintenance
50h-check
page
–
For new machine, checks shall be performed after 50h operating time.
Checks are performed to increase the machine’s reliability.
In addition to the following checks, lubrication should also be per-
formed according to 500h service, see Lubrication 500 hours page 17.
1 Engine Reference
Bolted joints, attachments, mountings, hose clamps, wear and chafing
of hoses, cable harnesses, etc.
Fuel pre-filter, water draining Section 1 Engine, group 1.2.3 Fuel pre-filter
Fan belt tension, check Section 1 Engine, group 1.7.5 Cooling fan
2 Transmission
Leakage check
3 Driveline/axle
Mounting propeller shaft, check-tightening Section 3 Driveline/axle, group 3.2 Propeller shaftl
Mounting drive axle, inspection Section 3 Driveline/axle, group 3.3 Drive axle
4 Brakes
Leakage check
5 Steering
Sensor, steering wheel angle, mini-wheel/lever steering, function Section 5 Steering, group 5.2.11 Sensor steering
check wheel angle
6 Suspension
Steering axle suspension, check Section 6 Suspension, group 6.2.1 Steering axle
cradle
7 Load handling
Hose connections, check-tightening in case of leaks
8 Control system
Check that there are no active error codes Section 8 Control system, group 8.3 Error codes
Climate control system, performance test Section 9 Frame, body, cab and accessories,
group 9.4 Air conditioning
10 Common hydraulics
Hose connections, check-tightening
11 Common electrics
Batteries, check Section 11 Common electrics, group 11.3.1 Start
battery
Service schedule
page
–
Service shall be performed every 500 operating hours. Actions are di-
vided into 500h, 1000h and 2000h service.
Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.
Actions for 1000h service are performed at odd thousands of operat-
ing hours: 1000h, 3000h, 5000h, etc.
Actions for 2000h service are performed at even thousands of oper-
ating hours: 2000h, 4000h, 6000h, etc.
After completed service a note shall be made in the Check and service
log, see Check and service log page 4.
In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h = operating hour
CAUTION
The lubrication interval is based on normal handling
and environment and requires use of the recommend-
ed grades and quantities.
General
Leakage check C C C
Fuel pre-filter C C/R C/R Drain water/ impurities. Section 1 Engine, group
1.2.3 Fuel pre-filter
Turbo C
Air filter main cartridge C/R C/R C/R Check indicator, change fil- Section 1 Engine, group
ter at indication. 1.6.1 Air cleaning system
Air filter safety cartridge C C/R C/R Change every second time
the main insert is changed.
Drive belts C C/R C/R Change when needed. Section 1 Engine, group
1.7.5 Cooling fan
Engine oil filter R R R Change the filters during Section 1 Engine, group
each oil change. 1.8.4 Oil filter
Fuel pre-filter C C/R C/R Drain water/ impurities. Section 1 Engine, group
1.2.3 Fuel pre-filter
Air filter main cartridge C/R C/R C/R Check indicator, change fil- Section 1 Engine, group
ter at indication. 1.6.1 Air cleaning system
Air filter safety cartridge R C/R C/R Change every second time
the main insert is changed.
Drive belts C/R C/R C/R Change when needed. Section 1 Engine, group
1.7.5 Cooling fan
Drive belt tensioner C/R C/R Check after 1000h / every
year. Change when need-
ed.
Engine oil filter R R R Change the filters during Section 1 Engine, group
each oil change. 1.8.4 Oil filter
2 Transmission
Transmission oil C R R Section 2 Transmission,
group 2.6 Lubrication
3 Driveline/axle
Propeller shaft C C C Section 3 Driveline/axle,
group 3.2 Propeller shaft
4 Brakes
Servo brake C C C Function check.
Parking brake C/R C/R C/R Check pad thickness, Section 4 Brakes, group
change when needed. 4.5.4.2 Parking brake pads
5 Steering
Link arms C C C Check bearings and the Section 5 Steering, group
shafts lock plate. 5.2.6 Link arms
6 Suspension
Steering axle mounting C C Mounting in frame. Section 6 Suspension,
group 6.2.1 Steering axle
cradle
7 Load handling
Mast mounting C C Check that the welding is Section 7 Load handling,
intact and check the bear- group 7.2.6 Mast
ings.
C C C
Sensor
8 Control system
Service indicator, reset C C C Special code in addition to Section 8 Control system,
service code required. group 8.2.4 Service indica-
tor.
Fresh air filter C/R R R Dependent on external en- Section 9 Frame, body,
vironment. cab and accessories,
Some models have washa- group 9.4.4 Fresh air filter
ble pre-filters. Fine filter re-
placed as needed.
Hydraulic tipping of cab C C C Check pin for cab and lift Section 9 Frame, body,
cylinder mounting. cab and accessories,
group 9.10.3 Cab mounting
Section 9 Frame, body,
cab and accessories,
group 9.10.4 Cab tilt
10 Common hydraulics
Accumulator C C C Check precharge pres- Section 10 Common hy-
sure. draulics, group 10.3.2 Ac-
cumulator
Hydraulic oil C/R Check with oil sample. Section 10 Common hy-
• If oil sample OK after draulics, group 10.6.9 Hy-
2000h, run another draulic oil, check.
1000h and take new
oil sample.
• If oil sample OK after
3000h, run another
1000h and change oil.
Note: Max. 4000h change
interval.
Additive: Lubrizol should
be added when changing
hydraulic oil. Concentra-
tion 3%.
For volume and quality,
see section F Technical
data
11 Common electrics
Position sensor C C C Must be free from grease
and dirt, clean as neces-
sary
Washing
page
–
CAUTION
When using a high-pressure washer to clean the ma-
chine, do not aim the water jet directly at the radiator,
linkages, bearings or electrical components, for ex-
ample, control units, connectors and sensors.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's grease points are lubricated, see
section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
6
5
7 15 15
3 4
2 8
2 2
3
16 16
9,11
10
9
12
1 14 13 007872
7 Chain wheel
8 Lifting chains
9 Support rollers and fork wheels, forks Support rollers, forks page 20
13 Mast wheels
14 Mast anchorage
Cab locks
1 Tip the cab.
2 Lubricate the cab locks with grease.
007874
Hinges, doors
3 Lubricate the door hinges with grease. Lift the door to facilitate
greasing.
Lubricate the mechanism in the engine hood.
Brake pedal
5 Lubricate the brake pedal hinge using grease.
6 Wipe off surplus grease.
Link arms
10 Lubricate the link arm bearings with grease.
1 1
3 3
2 2
007869
4
007870
4
DCD 200-250 DCD 280-300
1. Lubrication point, upper king pin bearing 3. Lubrication point, outer link bearing
2. Lubrication point, inner link bearing 4. Lubrication point, lower king pin bearing
Tilt cylinders
11 Lubricate the tilt cylinder axles with grease. There is a lubrication
point at each end of the tilt cylinder.
007871
Mast
12 Start the machine and lift the mast, for better access to the lubri-
4 3 cation points.
13 Stop the engine.
4
14 Support the mast securely.
15 Lubricate slide plates (position 1), support rollers (position 2),
chain wheels (position 4) and mast wheels (position 5), and also
top support rollers (position 3) when fitted, with grease, please re-
fer to insert F Technical data.
1 If there are lowered grease points, the top support rollers and
2 16 Brush or spray the chains with chain oil. Make sure that the
chains are well lubricated.
5
007275
Mast anchorage
17 Unload the mast anchorage in a suitable manner. Unload it by do-
ing one of the following:
– Put a jack under the stand and lift, so that the stand does not
hang from the stand anchorage.
– Tilt the stand back, put something under the stand that can
support the load, then tilt forwards again.
18 Lubricate the mast anchorage with grease.
007868
2 2
1
1
3
4
6
007925
Side lift attachment
19 Grease all slide surfaces using slide grease (pos. 1) with the at-
tachment in max. extended position.
20 Grease the hydraulic cylinders using universal grease (pos. 2).
21 Grease the twistlock cylinders using universal grease (pos. 3).
22 Grease the twistlocks using universal grease (pos. 5).
23 Grease the contact pins using universal grease (pos. 6).
4 1 3 3
2 2
007873
3
3 Wheel bearings, steering axle See Wheel bearings, steering axle page 26
6
Side lift attafchment (not positioned in figure) See Side lift attachment page 28
Hose wheels
1 Remove the securing plate to release the hose wheel.
2 Remove the hose wheels.
3 Smear the axle with slide grease.
4 Fit the hose wheels.
5 Fit the securing plate.
007876
King pin bearings
6 Lubricate the steering spindle bearing assemblies (upper and
lower) on both sides using grease.
If needed, turn the steering wheels for better acces.
1 1
3 3
2
2
007869
4
007870
4
1. Lubrication point, upper king pin bearing 3. Lubrication point, outer link bearing
2. Lubrication point, inner link bearing 4. Lubrication point, lower king pin bearing
NOTE
Work carefully so that the seal is not damaged.
Connectors
10 Grease the connectors with contact grease
006645
Connector, example
2 2
1
1
3
4
6
007925
Crack checking
page
–
DANGER
All welds on the machine must be checked at the rec-
ommended intervals. The interval is based on the as-
sumption that the machine is used in normal material
handling on a flat floor. In other operation, such as
when on rough ground, the interval should be short-
ened.
Examples of cracks
1. Linear crack
2. Point crack
Check points
Check the following welds extra carefully:
5
6
5
3
5
1
4
7 2
009467
Crack checking
8 Anchorage between frame member and rear section Anchorage between frame sides and rear section page 39
Mast anchorage
1
009485
DCD 200-250
a) Mast anchorage in chassis.
009486
DCD 280-300
b) Weld between mast member and attachment lug.
009487
009523
Tilt anchorage
2
a) Tilt anchorage on the mast
009481
009528
Machine with tilt arch
Driving axle anchorage
3
009483
DCD 200-250
a) Driving axle anchorage on chassis
009484
DCD 280-300
Lifting forks
4
NOTE
Other fork variants may be found, apart from the ones
shown here.
a) Fork mounting on vehicle members.
Support roller anchorages.
To check the material in the forks, please refer to section7
Load handling, group 7.9.1 Lifting forks.
009480
009529
Lifting equipment
5
NOTE
Other lifting equipment variants may be found, apart from
the ones shown here.
a) Weld between vehicle side and vehicle members.
009536
009479
d) Chain anchorage to the mast
Also check the chain tensioner, the fixing pin for the chain and
its split pin.
009478
009533
DCD 200-250
009534
DCD 280-300
Steering axle anchorage
7
a) Steering axle anchorage in chassis.
a
b) Steering axle anchorage on steering axle subframe.
b
009525
009532
b) Anchorage between frame sides and rear section, seen from
009531
underneath.
0 Complete machine
Complete machine
mm mm mm mm mm mm
The Kalmar DCD 200-300 is a forklift truck. The machine has a lifting
capacity of 20–30 tons depending on design.
The engine is a six cylinder four-stroke direct-injected diesel engine.
The transmission is hydromechanical with gear wheels constantly
meshed. It has three forward gears and three reverse gears. The pow-
er is transferred using a torque converter.
The driveline/axle consists of a propeller shaft and a rigid drive axle
with hub reduction. Drive takes place on the front wheels.
The service brake is of the type disc brake in oil which is built together
with the driving wheel's wheel hub. The parking brake is of the type
disc brake and acts on the drive axle's input shaft.
Steering takes place on the rear wheels with a double-acting hydraulic
cylinder. The steering axle is oscillation-mounted in the frame.
The wheels are secured to the hubs with nuts and washers. There are
double wheels on the drive axle, and single on the steering axle. The
wheels have split rims.
Load handling comprises components and functions for managing
loads. Loads are lifted with forks, secured to the carriage attached to
a mast. The load handling is divided into functions lift and lower, tilt,
sideshift, spreading, levelling and carrying loads. Lift and lower is the
function to raise and lower the fork carriage. Side shift is to move the
forks parallel at the same distance with each other laterally along the
carriage. Spreading is to adjust the width between the forks on the car-
riage. Tilt is to angle the load in the machine's longitudinal direction us-
ing the mast. Levelling is to angle the load laterally to the machine.
Load carrying is to grasp the load.
The control systems are functions for warning the operator of danger-
ous situations and faults. The control system has diagnostic resources
that simplify troubleshooting.
The frame carries the machine. Within the frame the engine, transmis-
sion, drive axle, steering axle etc. are secured. On the side of the
frame are tanks for fuel and hydraulic oil. The cab is located centrally
and can be tipped laterally.
1 Engine
1 Engine ............................................................................................................. 3
1.2 Fuel system .............................................................................................. 11
1.2.1 Fuel tank .............................................................................................. 13
1.2.2 Fuel filter .............................................................................................. 14
1.2.3 Fuel pre-filter ........................................................................................ 16
1.3 Device for extra exhaust emission control ................................................ 18
1.3.1 Particle filter ......................................................................................... 18
1.5 Mechanical parts ...................................................................................... 19
1.5.4 Valve mechanism ................................................................................ 19
1.5.6 Crank mechanism ................................................................................ 23
1.6 Air intake and exhaust outlet .................................................................... 24
1.6.1 Air cleaning system .............................................................................. 24
1.6.3 Exhaust system ................................................................................... 26
1.6.4 Intercooler ............................................................................................ 27
1.7 Cooling system ......................................................................................... 29
1.7.4 Radiator and expansion tank ............................................................... 29
1.7.5 Cooling fan ........................................................................................... 30
1.7.7 Coolant ................................................................................................ 34
1.7.9 Sensor coolant temperature ................................................................ 40
1.8 Lubrication ................................................................................................ 41
1.8.3 Sensor oil pressure .............................................................................. 41
1.8.4 Oil filter ................................................................................................. 42
1.9 Control system engine .............................................................................. 44
1.10 Ignition/heating ......................................................................................... 45
1.11 Start/stopp ................................................................................................ 46
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
The engine provides power for propulsion and working hydraulics. The
following engine alternatives are available:
• Volvo TAD750VE (182 kW).
• Cummins QSB6.7 (194 kW).
Emission requirements
The low emission engines have a new design of combustion bowl, in-
jection equipment and charge air cooler that mean that they meet
emission requirements from USA (California) and Europe. With the
new engines a significant improvement is achieved, not just with ex-
haust emissions, but also with the output curve and the torque curve.
Noise requirements
The engines fulfil the noise and vibration requirements in force
(EN13059).
0
P I
II
III ˚C
. bar
7 <˚ 1
rpm
<˚
10 kph
ECU790
4
9 F
EDU795 R
R
1 2 3
4 5
ECU793
11
ECU794
2
007970
5 M 3 6 SENSORS 8 H2O
0
P I
II
III ˚C
H2O
11 . bar
<˚ 1
8 rpm
<˚
10 kph
ECU790
5
9 F
EDU795 R
R
1 2 3
4 5
ECU793
4
ECU794
2
6 M SENSORS
008000
3 7
position
1 2 3 6
4
10b
9
0
P I
8 II 7
10a III
009569
Electric components machine
13
12
11
10
9
4 14
15
16
3 17
18
19
20
2 21
22
23
24
007975
1 25
10
9
8
7
6
5
4
007976
Volvo TAD750VE, right side (in machine's travel direction)
6 7
8
9
10
11
12
3 13
14
2
15
007397
1 16
7
6
8
10
5
11
4
12
13
14
15
007396
16
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
A
001537
The fuel system must be bled, e.g., after fuel filter replacement, if the
fuel tank has been run dry or after long periods of operation.
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
Volvo TAD750VE
Cummins)
The fuel system must be bled, e.g., after fuel filter replacement, if the
fuel tank has been run dry or after long periods of operation.
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
Cummins QSB6.7
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
On the top side of the tank is a manhole cover to allow the tank to be
cleaned.
1. Machine in service position, see section B Safety.
2. Empty the fuel out of the tank. Use a pump.
3. Remove the drain plugs under the fuel tank.
4. Flush the fuel tank clean through the fuel filler hole.
5. Put the drain plugs back.
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
NOTE
Do not fill the new fuel filter with fuel before installing. There
is a risk that impurities may enter the fuel system, resulting
in malfunctions or damage.
5 Fit the new filter to the engine.
Tighten the fuel filter in accordancewith the instructions on the
fuel filter
6 Bleed the fuel system if necessary, see Fuel system, bleeding
(engine alternative Volvo) page 12.
7 Start the engine and check carefully that no leakage occurs.
006434
Volvo TAD750VE
Fuel filter
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
NOTE
Do not fill the new fuel filter with fuel before installing. There
is a risk that impurities may enter the fuel system, resulting
in malfunctions or damage.
5 Fit the new filter to the engine.
Tighten the fuel filter on by hand until the rubber seal just touches
008003
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
1 Machine in service position, see section B Safety.
2 Unscrew the water reservoir, empty any water and clean the res-
ervoir.
3 Unscrew the filter cartridge.
4 Check that the new filter cartridge is absolutely clean and that the
seal is undamaged. Wipe a film of oil on the gasket.
5 Screw the filter cartridge together with the water reservoir and in-
stall them on the filter bracket.
6 Bleed the fuel system, see Fuel system, bleeding (engine alter-
native Volvo) page 12.
1 7 Start the engine and check carefully that no leakage occurs.
008066
Volvo TAD750VE
1. Fuel pre-filter.
Volvo)
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
NOTE
The fuel pre-filter should be drained of water daily.
1
008067
Volvo TAD750VE
Cummins)
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
Cummins QSB6.7
1. Fuel pre-filter.
Cummins)
NOTE
Read the safety instructions for fuel system before working, see
section B Safety.
NOTE
The fuel pre-filter should be drained of water daily.
NOTE
When closing the drain valve, do not overtighten the valve.
Overtightening can damage the threads.
008004
1
3 Close the drain valve by lifting the valve and turn clockwise until
it is hand-tight, bleed the system, see Fuel system, bleeding (en-
Cummins QSB6.7 gine alternative Cummins) page 13.
4 Start the engine and check carefully that no leakage occurs.
Every year or every 1500nd hour the particle filter should be cleaned
of fuel and lubricant residue in accordance with the following:
1 Clean burn the filter as normal, see Operator’s manual DCD 200–
300.
2 Allow the filter to cool for 3–4 hours.
3 Detach the clamps and remove the filter section (centre section).
4 Set the filter section vertically and flush with water (not high-pres-
sure) from the outlet side. Flush thoroughly until the water is
clean.
5 Allow the water to run off thoroughly.
6 Refit the filter with new gaskets.
Cummins)
1 Machine in service position, see section B Safety.
2 Preperatory steps:
Disconnect the batteries.
3 Prior to removing any components, clean around the mounting
fasteners and sealing joints with compressed air to remove any
loose debris.
4 Remove:
Disconnect the breather tube connection at the back of the rocker
lever cover, Remove the capscrews to disconnect the breather
tube connection from the rocker lever cover.
008025
NOTE
Do not remove the rocker lever gasket on engines in which
the rocker lever cover gasket is fit into a groove at the base
of the rocker lever cover. The gasket is reusable. Once the
the gasket is removed from the rocker lever cover it must be
replaced.
Remove the mounting nuts and isolators from the rocker lever
cover.
008026
NOTE
If equipped, it may be necessary to gently pry the breather
tube connection from the back of the rocker lever cover
while removing.
Remove the rocker lever cover.
NOTE
Check the gasket while it is installed in the valve cover.
Once the gasket is removed from the cover it must be re-
placed.
Check the gasket for cracks on the sealing surface. Replace the
gasket if damage is present or it has been removed from the
groove in the rocker lever cover.
008027
7 If replacing the rocker lever gasket, the following installation pro-
cedure must be used when installing the press-in gasket:
1. Press the molded gasket into the corners of the rocker lever
cover.
2. Press the remaining gasket into the rocker lever cover.
008029
9 Adjust
NOTE
Engine coolant temperature must be less than 60°C.
Using the barring tool, Part Number 3824591, rotate the crank-
shaft until the Number 1 cylinder is at TDC.
TDC can be determined by the following method:
008030
NOTE
The TDC indicator is on the vibration damper/crankshaft
speed indicator ring.
Align the vibration damper/crankshaft speed indicator ring so that
the TDC indicator is at the 12 o´clock position. If both number 1
cylinder rocker levers are loose, move to the following steps. If
both number 1 cylinder rocker levers are not loose, rotate the
crankshaft 360 degrees.
NOTE
008031
Cylinder 1 is the cylinder closest to the fan.
10 With the engine in this position, lash can be checked on the fol-
lowing rocker arms:
(E = exhausts, I = intake)
Cylinder 1I, 1E, 2I, 3E, 4I and 5E.
008032
11
NOTE
008033
NOTE
The clearance is correct when some resistance is “felt”
when the feeler gauge is slipped between the crosshead
and the rocker lever socket.
Lash specifications
mm
Intake 0.254
Exhaust 0.508
008034 13 Using barrel tool, Part Number 3824591, rotate the crankshaft
360 degrees.
Following the same steps and specifications as previously stated,
measure lash for the following rockers:
(E = exhausts, I = intake)
Cylinder 2E, 3I, 4E, 5I, 6I and 6E.
008030
14 Install:
Install the rocker lever cover over the mounting capscrews.
Install the isolators and mounting nuts.
Tighten the mounting nuts and torque to 24 Nm.
008026
alternative Cummins)
CAUTION
The silicone fluid in the vibration damper will become
solid after extended service and will make the damper
inoperative. An inoperative vibration damper can
cause major engine or drivetrain failures.
Check the vibration damper for evidence of fluid loss, dents, and wob-
ble. Inspect the vibration damper thickness for any deformation or rais-
ing of the damper cover plate.
If any of these conditions are identified, contact your local Cummins
Authorized Repair Location to replace the vibration damper.
For vibration damper location, see Engine, component position (en-
gine alternative Cummins QSB6.7) page 9.
008038
A
A
C C
001539
B
A. Position for air filter housing
B. Change indicator
009555
C. Soot outlet
3 Check that the dust ejector has emptied itself. Otherwise, empty
the ejector.
4 Clean the outside of the air filter housing
5 Remove the cap from the air filter housing.
NOTE
Filter must be changed, not cleaned.
9 Fit the cover to the air cleaner casing.
10 Check that the hoses from the cleaner casing are sealed.
11 Reset the air filter indicator, press the button on the top side.
WARNING
Hot exhaust system! When the machine is operated
the exhaust system, and mainly the turbo and silenc-
er, become scorching hot.
1.6.4 Intercooler
Intercooler, check
page
–
CAUTION
Avoid the intercooler when using a power washer.
NOTE
Do not use a high-pressure washer.
4 Check that the intercooler mounting is intact.
5 Check that hoses and clamps for the intercooler are in good con-
dition and that no leakage exists.
NOTE
If there is oil in the charge air hoses, the intercooler and all
pipes and hoses in the charge air system must be cleaned
very carefully before the engine is started.
NOTE
Do not use a high-pressure washer.
NOTE
Avoid the fuel cooler.
4 Check that the cooling flanges are intact.
Inspection should be done after operation, when the belts are hot.
Check the belts for intersecting cracks. Tranverse (across the belt
width) cracks are acceptable, Longitudinal (direction of the belt length)
cracks that intersect with transverse cracks are not acceptable. Re-
place the belt if it is frayed or has pieces of material missing. See Drive
belt changing (engine alternative Volvo) page 30 or Drive belt chang-
ing (engine alternative Cummins) page 31 for belt adjustment and re-
placement.
Belt damage can be caused by:
008011 • Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating enviroment
• Oil or grease on the side of the belts
It should be possible to press the alternator belts and drive belts down
about 3-4 mm (0.12-0.16") betweenthe pulleys.
The alternator belts and drive belts have automatic belt tensioners and
do not need to be adjusted.
IMPORTANT
Always change a drive belt which appears worn or
cracked
008012
Volvo TAD750VE
007969
Volvo TAD750VE
NOTE
The belt tensioner winds in the direction that the spring tang
is bent over the tensioner body. To loosen the tension on the
belt, rotate the tensioner to wind the spring tighter.
CAUTION
008013
3. Lift the tensioner and install the drive belt. If difficulty is experi-
enced installing the drive belt (the belt seems to short), position
the belt over the grooved pulley first; then, while holding the ten-
sioner up, slide the belt over the water pump pulley.
Undo the belt tensioner. Check that the belts are correctly aligned
in their grooves and are correctly tensioned.
Cummins)
With the engine turned off, check that neither the top nor the bottom
tensioner arm stop is touching the cast boss on the tensioner body. If
either of the stops is touching a boss, the alternator belt must be re-
placed. Check to make certain the correct belt part number exists.
008014
Check the tensioner pulley and body for cracks. If any cracks are no-
ticed, the tensioner must be replaced. See Supplier documentation
engine.
Check the tensioner for dirt buildup. If this condition exists, the tension-
er must be removed and steam cleaned.
008015
With the cooling fan belt removed, check that the bottom tensioner arm
stop is in contact with the bottom tensioner arm stop boss on the ten-
sioner body. If these two are not touching, the tensioner must be re-
placed.
008016
Inspect the tensioner for evidence of the pivoting tensioner arm con-
tacting the stationary circular base. If there is evidence of these two ar-
eas touching, the pivot tube bushing has failed and the tensioner must
be replaced.
008017
The worn tensioner that has play in it or a belt that “walks” of its pulley
possibly indicates pulley misalignment.
NOTE
Maximum pulley misalignment is 3 degrees
This measurement can be taken with a straight edge and an inclinom-
eter.
Install the belt.
008018
Fan hub, check (engine alternative Cummins)
page
–
NOTE
The fan hub must rotate without any wobble or excessive
end play.
1.7.7 Coolant
Coolant, check
page
–
NOTE
Read the safety instructions for cooling system before working,
see section B Safety.
NOTE
The coolant must comprise water and at least 40 percent
volume glycol antifreeze in those countries where the tem-
perature can fall below 0 °C. The glycol antifreeze content
must not exceed 60 percent volume in mixed coolant.
If only glycol antifreeze and water have been used as cool-
ant then the value must exceed -15 °C or 30 percent volume
C A B
for the corrosion protection to be adequate.
4 Check the coolant level, the level must be between MAX and
MIN.
MAX
NOTE
The coolant level must be checked on a engine cold.
MIN
001540
alternative Volvo)
Cooling performance is reduced by deposits in the radiator and cool-
ing galleries. The cooling system should be cleaned out when the cool-
ant is changed.
IMPORTANT
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have any frost prevention ability.
NOTE
Read the safety instructions for cooling system before working,
see section B Safety.
NOTE
The engine must be stopped before draining, and the filler cap
unscrewed.
1 Remove the filler cap from cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block, using the drain hose.The drain nipples are situated
under the radiator on the right side of the engine block.
3 Check that all coolant drains out.
NOTE
Deposits may be found inside the drain plug/tap, and need
to be cleared away. There is otherwise a risk that cool-ant
could remain and cause frost damage.
Check whether the installation has any further taps or plugs at the
007394
lowest points of the cooling water pipes. Leave the drain taps /
plugs open and make sure that the heater is set to full heating
Volvo TAD750VE while it is being cleaned.
4 Put a hose into the filling hole in the expansion tank and flush with
pure water, until the water which runs out is completely clear.
5 If there should still be some contamination left after flushing for a
long time, cleaning can be done with coolant. Otherwise, contin-
ue as in item 10 below.
6 Cleaning with coolant:
Fill the cooling system with 15-20% mixture of concentrated cool-
ant. Only use the recommended concentrated coolant, mixed
with pure water.
NOTE
To prevent suspended material from settling back in the system,
emptying should be done rapidly, within the space of 10 minutes,
when the engine has not been standing still for a long time. Re-
move the filler cap from the expansion tank and possibly the low-
er radiator hose to increase the speed of emptying.
8 Flush the system at once, very carefully, with pure hot water to
stop dirt from settling on the inner surfaces again. Flush until the
water that runs out is completely clean. Make sure that any heat-
er controls are set to full heating during emptying.
9 If contamination should still be left after a long period of flushing,
you can do a clean-out with radiator cleaner, followed by finish-
ing-off with neutraliser.
NOTE
Only use cleaning material approved by the engine manu-
facturer. Follow the instructions on the package carefully.
10 When the cooling system is completely free from contamination,
close the drain taps and plugs.
NOTE
Only use recommended coolant.
IMPORTANT
It is extremely important that the correct concentra-
tion and volume of coolant is put in the system. Mix in
a separate clean vessel before filling the cooling sys-
tem. Make sure that the liquids mix.
11 Fill up with coolant, so that the level ends up between the MIN
and MAX markings. Do not start the engine until the system is
vented and completely filled.
12 Start the engine when the cooling system has been completely
filled and bled.
Open all heater controls on the heater unit, to ensure that it is
vented.
13 Stop the engine after about an hour and check the coolant level.
Top up as necessary.
alternative Cummins)
Cooling performance is reduced by deposits in the radiator and cool-
ing galleries. The cooling system should be cleaned out when the cool-
ant is changed.
IMPORTANT
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have any frost prevention ability.
NOTE
Read the safety instructions for cooling system before working,
see section B Safety.
NOTE
The engine must be stopped before draining, and the filler cap
unscrewed.
1 Remove the filler cap from cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block. One drain nipple is situated under the radiator and an-
other one on the underside of the coolant inlet on the engine
block.
3 Check that all coolant drains out.
NOTE
Deposits may be found inside the drain plug/tap, and need
to be cleared away. There is otherwise a risk that cool-ant
could remain and cause frost damage.
008020
Check whether the installation has any further taps or plugs at the
lowest points of the cooling water pipes. Leave the drain taps /
plugs open and make sure that the heater is set to full heating
while it is being cleaned.
4 Stop the engine after about an hour and check the coolant level.
Top up as necessary.
CAUTION
The system must be filled properly to prevent air
locks. During filling, air must be vented from the en-
gine coolant passages. Wait for 2 to 3 minutes to al-
low the air to be vented; then add mixture to bring the
level to the top.
5 Cleaning:
NOTE
Do not install the radiator cap. The engine is to be operated
without the cap for this process.
Fill the system with a mixture of sodium carbonate and water (or
a commercially available equivalent).
NOTE
008021
Use 0.5 kg of sodium carbonate for every 23 liters of water.
NOTE
Be sure to vent the engine for complete filling.
NOTE
Do not install the radiator cap.
008022
NOTE
If the water being drained is still dirty, the system must be
flushed again until the water is clean.
9 When the cooling system is completely free from contamination,
close the drain taps and plugs.
NOTE
Only use recommended coolant.
NOTE
Never use water alone for coolant. Damage from corrosion can
be the result of using water alone for coolant.
IMPORTANT
It is extremely important that the correct concentra-
tion and volume of coolant is put in the system. Mix in
a separate clean vessel before filling the cooling sys-
tem. Make sure that the liquids mix.
10 Fill:
Fill up with coolant, so that the level ends up between the MIN
and MAX markings. Do not start the engine until the system is
vented and completely filled.
11 Start the engine when the cooling system has been completely
filled and bled.
Open all heater controls on the heater unit, to ensure that it is
vented.
12 Stop the engine after about an hour and check the coolant level.
Top up as necessary.
Coolant, mixing
page
–
NOTE
Read the safety instructions for cooling system before working,
see section B Safety.
IMPORTANT
Ethylene glycol must not be mixed with other types of
glycol.
Mix:
50% glycol.
50% water.
This mixture prevents against internal corrosion, cavitation and frost
bursting down to about -36°C and a boiling point up to 108°C. (At 60%
glycol concentration, the freezing point is lowered to -54°C. Never mix
more than 60% concentrate in the coolant. This will give reduced frost
protection and poorer cooling effect, with a consequent risk of over-
heating.
IMPORTANT
The coolant must be mixed with pure water.
007395
IMPORTANT
It is extremely important that the correct concentra-
tion and volume of coolant is put in the system. Mix in
a separate clean vessel before filling the cooling sys-
tem. Make sure that the liquids mix.
NOTE
It is important that the coolant is correctly mixed, all year round,
to ensure full protection against corrosion. The corrosion protec-
tion properties fall as time passes, so the coolant must be
changed at the specified intervals.
1.8 Lubrication
Lubrication, description
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Always follow the recommended oil change interval and always
change the oil filter during oil changes.
1 Run the engine until warm.
2 Machine in service position, see section B Safety.
3 Remove the drain plug on the engine and drain the engine of oil.
4 When the engine oil has drained, install the oil plug with new gas-
ket. Torque with max. 79 Nm for engine alternative Volvo and
with 80 Nm for engine alternative Cummins.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
5 Change oil filter, se Oil filter, changing page 42.
6 Fill up with oil to the correct level. For volume and grade, see sec-
tion F Technical data.
007317
NOTE
Do not fill over the MAX level.
7 Start the engine and let it idle. Check that the oil pressure is nor-
mal.
8 Stop the engine, check the oil level, see Oil level, checking page
43 and that no oil leakage occurs around the filters. Top up with
oil as necessary.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Oil filters must be changed at every oil change
1. Drain the oil, see Engine oil, change page 41.
007360
no more.
Engine alternative Cummins 5. Top up with oil, see Engine oil, change page 41
6. Start the engine and check that no oil leakage occours.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
The engine's fill poin (position B) and oil dipstick (position A) are lo-
cated under the engine hood, for engine alternative Volvo on the left-
hand side and for engine alternative Cummins on the right-hand side.
009554
Volvo TAD750VE
A. Oil dipstick
B. Fill point engine oil
1 Machine in service position, see section B Safety.
2 Check the oil level when the engine is warm. The oil dipstick has
two markings, MAX. and MIN., the oil level should be between
these markings.
Wipe off the oil dipstick before checking.
3 Fill engine oil (position B) as needed (for volume and oil quality,
see section F Technical data).
4 The recommendation is that engine oil is filled when the engine
and oil are at operating temperature. Fill – wait awhile – check on
the oil dipstick.
NOTE
Work carefully when filling to prevent other fluids or particles
from contaminating the engine oil, which means risk of en-
B
gine damage.
007390
Cummins QSB6.7
A. Oil dipstick
B. Fill point engine oil
The engine is controlled by a control system, for which the central unit
is a control unit.
The system is among other things sensors, control unit and elektrical
injectors. Sensors sends information to the control unit which controlls
the fuel injectors.
Control unit receives information about the engines condition from the
following components:
• Camshaft position sensor
• Flywheel position and speed sensor
• Sensor coolant temperature
• Sensor charge pressure and temperature
• Sensor oil pressure
• Sensor water-in-fuel
• Sensor fuel pressure
• Sensor low fuel pressure (only applies to engine alternative Volvo)
• Sensor coolant level (only applies to engine alternative Volvo)
• Sensor ambient air temperature (only applies to engine alternative
Volvo)
• Sensor barometric pressure (only applies to engine alternative
Cummins)
Based on this information control unit controls:
• injection time
• electronic pre-heating (heater plug)
If a serious problem is detected by the control system for the engine,
engine power is reduced to protect the engine from further damage.
Signals from the sensors gives exact information about the engines
present condition and makes it possible for the processor in the control
unit, to among other things calculate the correct amount of fuel needed
and control the engine status.
For further information about control unit engine, see section 11 Com-
mon electrics, group 11.5.3 Control units and supplier documentation
engine.
1.10 Ignition/heating
Ignition/heating, description
page
–
The engine is equipped with preheating of the inlet air, for faster start
at low temperatures. Preheating is activated when the starter key is in
position I. When preheating is activated, the preheating symbol is lit in
the display. The ignition sends signals to Control unit General
(ECU790) which sends messages via the CAN-bus link to the engine
control unit (ECU794).
For an overview with the locations of engine sensors, see Engine,
component position (engine alternative Volvo TAD750VE) page 7 or
Engine, component position (engine alternative Cummins QSB6.7)
page 9.
1.11 Start/stopp
Start/stop, general
page
–
NOTE
The battery disconnect switch cannot be used as emergency
stop!
A. Battery disconnect switch
B. Sign to depict battery disconnect switch in ON position, i.e. main
electric power connected, and battery disconnect switch in OFF posi-
tion, i.e. main electric power disconnected
C. Handle to open/close cover
001549
A B C
2 Transmission
2 Transmission.................................................................................................. 3
2.3 Mechanical transmission ............................................................................ 6
2.6 Lubrication system ..................................................................................... 7
2.6.4 Oil filter ................................................................................................... 9
2.7 Cooling system ......................................................................................... 10
2.8 Transmission control system .................................................................... 11
2 Transmission
mm mm mm mm mm mm
The transmission converts the engine power to the drive wheels (drive
axle) via the propeller shaft and also power to drive the hydraulic oil
pumps for the hydraulic system.
The transmission is manual with torque converter. The transmission
has three speeds in each direction.
The torque converter and the transmission work together via a com-
mon hydraulic system. The torque converter is a hydraulic clutch
placed between the engine's output shaft and the transmission's input
shaft. The hydraulic oil pumps as well as the oil pump for the transmis-
sion's control and lubrication are mounted on the torque converter, but
are directly connected to the input shaft of the torque converter, i.e.
they are directly driven by the engine and are not affected by the
torque converter.
Gear positions are selected by pressure modulation with electrical
valves that are controlled by Control unit transmission (ECU793). The
control unit uses sensors for pressure, temperature and speeds to de-
termine which gear position shall be activated as well as solenoid
valves to activate the gear.
F
R
1 F
3 D2 N
18 R
D3 <˚ D1 R
6 1
4
2
5
3
D5 20
D4 ECU790
19 Pa
2 16
EDU795
9 17
ECU793 ECU794
5
15
009542
1. Gear selector (S160) 11. Sensor turbine speed (B751)
3. Switch parking brake (S107) 13. Sensor output shaft speed (B758)
8. Sensor engine speed and oil temperature (B753) 18. Inching pedal
10. Solenoid valves for travel direction and gear position 20.
Switch for inching (S220-1)
in valve block transmission control
1 2 3 4 5 6
5
9
10
11
8
15 12
14
007771
13
The transmission has its own lubrication system that is used for lubri-
cation, control and cooling of the transmission. The transmission oil
cooler is located at the bottom in the cooler unit behind the engine, a
thermostat in the cooler enables the oil to reach operating temperature
faster.
At high oil temperature (100 °C) a warning is activated in Control unit
terminal (ECU795) and performance is reduced, if the oil temperature
goes above 125 °C the transmission is disengaged.
For component positions, please refer to Transmission, component
position page 5.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be overfilled!
NOTE
The oil filter must be changed at the same time as an oil change
is done.
1 Operate and warm up the transmission oil.
2 Machine in service position, see section B Safety.
3 Stop the engine and turn the main switch off.
4 Place a receptacle under the transmission and let the oil drain
into the receptacle.
5 Remove the drain plug from the transmission.
6 Clean the drain plug and sealing surface on the transmission.
7 When the transmission oil has drained, fit the drain plug.
NOTE
Make sure that the washer for the oil plug is included.
8 Remove the transmission oil dipstick and fill new transmission oil
through the oil dipstick's hole to the marking for low level on the
dipstick.
For volume and quality, see section F Technical data.
9 Start the engine and let it idle for at least two minutes.
10 Check that the drain plug for transmission oil seals tight.
11 Check the transmission oil level with the engine running at idle
(600 rpm) and the transmission in neutral position. Top up to the
marking for low level.
NOTE
After an oil change, we recommend that the transmission should
Operation menu oil temperature be calibrated, please refer fo Transmission, calibration page 12.
a. Transmission oil temperature
b. Battery voltage
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be overfilled!
Special tools: filter tool
Equipment: collection vessel (5 l)
1 Machine in service position, see section B Safety.
2 Place a collection vessel underneath the transmission oil filter.
3 Remove the transmission oil filter, pour out the oil in the collection
vessel.
4 Moisten the O-ring on the new filter with clean transmission oil.
5 Fit the new transmission oil filter.
Tighten to contact and then a further two-thirds revolution.
6 Switch on the main circuit and start the engine.
7 Check that no leakage occurs.
8 Check the oil level, see Transmission oil, changing page 7
Mode Limp-Home
Display on Control unit transmission shows LH.
In case of:
• a malfunction of a control output from the transmission is detect-
ed.
• a malfunction connected to a sensor for “engine speed” is detect-
ed.
• two of three “vehicle speed” sensors are defective.
In case any of the above points occur, the transmission will be placed
in neutral position. To enable continued operation, gears have to be
selected using the gear selector.
In this mode the operator can use the transmission's two first gears in
both directions. If the malfunction occurs at a higher gear, the operator
has to downshift manually to first or second gear to continue.
The control unit uses standard values for modulation.
Mode Shut-Down
Display on Control unit transmission shows “Sd”.
The transmission has a built-in secondary solenoid and pressure sen-
sor that monitor the transmission's internal oil pressure. The second-
ary solenoid is handled by the control unit.
When the control unit gives a control signal for “Shut-Down“, the oil
pressure releases for all pressure modulators. This happens in case
of a serious malfunction.
In this mode the transmission is in permanent neutral position as there
is no oil pressure to enable selection of a gear.
Transmission, calibration
page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
6 Select “Heat” by scrolling with the arrow keys (1 and 2) and con-
ECU793 D M firm with Enter.
E
007745
F S
F S
maximum acceleration for 20 seconds.
C. Engage neutral position and apply half throttle for 10 sec-
onds, run the engine at idling speed.
D. Repeat steps B and C until the oil temperature is over 60 °C
or max 90 °C. The temperature display starts to flash when
calibration of the clutches can start.
8 Check that the gear control is in neutral position.
9 Select “trAn” by scrolling with the arrow keys (1 and 2) and con-
ECU793 D M firm with Enter.
E 10 Start calibration by selecting travel direction forward.
007745
F S
007743
F S The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration then use the
foot brake to keep the machine stationary.
IMPORTANT
The transmission calibration process can be inter-
rupted at all times by moving the shift lever into the
reverse position.
F S 2 etc.
13 Depending on the actual calibrating mode, a different engine
speed may be required.
– Whenever the actual engine speed is too low following dis-
ECU793 D M play is shown:
E
007748
F S
– When the actual engine speed is too high, the display looks
ECU793 D M as follows:
E
007749
F S
14 Change the throttle pedal position until the display looks like left.
ECU793 D M After the engine has been within limits for about three seconds,
E the calibration process proceeds.
007750
F S
After successful completion of the calibration process, the
calibration results are memorised in Flash memory.
007751
F S each clutch (the first line corresponds to clutch1, the second line
to clutch2,…). A blinking line indicates the calibration of the cor-
responding clutch was no successful.
16 Turn off the ignition to store the values.
3 Driveline/axle
3 Driveline/axle .................................................................................................. 3
3.2 Propeller shaft ............................................................................................ 4
3.3 Drive axle ................................................................................................... 5
3 Driveline/axle
mm mm mm mm mm mm
Driveline/axle, description
page
–
• Clean.
• Check-tighten attaching bolts at mountings to:
– drive axle for DCD 200-250 with 98 Nm and DCD 280-300
with 133 Nm
– transmission with 98 Nm (oil)
• Check clearance in universal joints.
1
007803
1. Propeller shaft
The drive axle transmits the engine power to the wheels. After the
drive axle's input shaft is a differential which changes the reduction ra-
tio, distributes the power between right and left drive wheels and also
makes it possible for the drive wheels to rotate at different speed when
cornering. The drive shaft transmits the power from the differential to
the wheel hubs. There are hub reductions at the wheel hubs that
change the reduction ratio between wheel and engine to reduce the
stress on the drive shaft.
2
3
007809
DCD 200-250
1. Hub reduction
2. Drive shaft
3. Differential
4. Drive axle housing
2
3
007810
DCD 280-300
1. Hub reduction
2. Drive shaft
3. Differential
4. Drive axle housing
A
007804
DCD 200-250
3 Check-tighten the drive axle's attaching bolt (position A) with
1350 Nm.
007805
DCD 280-300
007806
7 Check if the wheel bearings in the driving axle are slack by:
– Lift the machine under the mast member. Install secure sup-
ports under the driving axle.
– Check if the wheel bearings in the driving axle are slack. If
there is any slack in the wheel bearings, they must be adjust-
ed, please refer to Workshop manual DCE 200-300.
NOTE
Read the safety instructions for oil before work, see section B
Safety.
NOTE
Make sure that the seal is in place
7 Repeat steps 1 and 6 on the other hub.
007845
NOTE
Read the safety instructions for oil before work, see section B
Safety
NOTE
The drive axle contains approx. 44 l of oil.
NOTE
Make sure that the sealing washers are in place.
9 Fill one hub with oil until the oil level is on the lower edge of the
filler hole.
007844
NOTE
The oil is very viscous and filling should be slow and the lev-
el checked in stages so that the oil has time to disperse.
10 Fit the hub reduction filler plug.
NOTE
Make sure that the sealing washer is in place.
11 Repeat steps 9 and 10 on the other hub.
007845
007846
Applies to DCD 200-250
13 Fill the differential with new oil until the oil is level with the filler
hole.
14 Fit the differential carrier assembly filler plug.
NOTE
Make sure that the sealing washer is in place.
15 Remove and clean the drive axle bleed valve.
16 Clean the axle of spilled oil.
17 Remove the collection container and the sheet metal plates. Han-
007847
4 Brakes
4 Brakes ............................................................................................................. 3
4.1 Controls and instrumentation ..................................................................... 4
4.1.1 Brake pedal ............................................................................................ 4
4.3 Servo brake system .................................................................................... 5
4.3.6 Distribution block ................................................................................... 8
4.5 Parking brake system ................................................................................. 9
4.5.4 Parking brake unit ................................................................................ 11
4.8 Temperature control, cleaning and hydraulic oil ....................................... 13
4 Brakes
mm mm mm mm mm mm
Brakes, general
page
–
There are brakes which are used to stop the machine. The brakes act
on the drive axle, (the steering axle has no brakes).
The brake system is divided into three functions:
• Power-assisted brake system, function description page 5
• Parking brake system, function description page 9
• Temperature control, cleaning and hydraulic oil, function descrip-
tion page 13
1 Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
2 Check that the brake pedal springs back sufficiently and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal's set screw to obtain the correct
clearance.
3 Check that the pedal's travel is smooth.
4 Check that the rubber on the pedal is intact and that the tread pat-
tern isn't worn out. Change if necessary.
description
The power-assisted brake system consists of a hydraulic oil tank, hy-
draulic oil pump, hydraulic oil filter, accumulator charging valve, accu-
mulator, brake valve, pressure sensors, brake cylinder and service
brake units.
The hydraulic oil pump pumps oil (from tank) which is cleaned in the
oil filter. The accumulator charging valve directs pressure to the accu-
mulators that store pressure or direct the oil to the load handling func-
tions. The brake valve directs pressure from the accumulators to the
brake cylinder. The brake cylinder compresses the discs in the brake
units that brake the machine. Switch (NC) brake pressure gives a sig-
nal so that the brake lights are activated when the brake cylinder is
pressurised.
Part of the return flow from the valve block is directed through the drive
axle's brake units and cools the brakes, and back to the tank. Pressure
from the accumulators is also used for the load handling servo circuit.
ECU790
12,14
D1
<˚ 13b D3
Pa
P
11 B 10
T 5
D2
16
Pa Pa
T 13a 9 8
B
7
P 6
15
X
C
4
C
2
3
D
P
ACK
007813
B
1. Hydraulic oil pump 10. Relay brake lights (K308-1)
2. Hydraulic oil filter 11. Switch normally open (NO), low accumulator pressure
3. Valve block, accumulator charging valve 12. Control unit general (ECU 790)
4. Brake valve 13a. Switch normally open (NO), declutch (S220)
position
1 2 3 6 8
P2
DS
M
OL
SP
4
D
PP
PL M
D6 LS
OL
SP
D
O
O
LS
AC DS
K P2
PP
5
AC PP
KM
13 12 11 10
009616
1. Hydraulic oil pump 8. Shuttle valve
2. Brake valve 9. Distribution block
3. Switch normally open (NO), low accumulator pres- 10. Wheel brake
sure
4. Switch normally closed (NC) brake lights (S216) 11. Hydraulic oil filter
5. Switch normally open (NO), declutch (S220) 12. Hydraulic oil tank
6. Valve block 13. Accumulator
7. Accumulator charging valve
The parking brake consists of hydraulic oil tank, hydraulic oil pump, hy-
draulic oil filter, accumulator charging valve, accumulator, pressure
sensors, and parking brake valve parking brake unit.
The hydraulic oil pump pumps oil (from tank) which is cleaned in the
oil filter. The accumulator charging valve directs pressure to the accu-
mulators that store pressure. The parking brake unit is released with
pressure from the accumulator by the parking brake valve pressurising
the parking brake calliper. Switch (NC) parking brake gives a signal so
that the indicator light parking brake is activated when the parking
brake is applied.
800 rpm N
0 km/h
10
13
F
N
EDU795
R
1 2
R
3 8 Pa
4 5
6 ECU790
D1
10,12 D2 5,11
7 B A 9
C
C 4
2
3
D
P
PPD
ACK
P 009607
1. Hydraulic oil pump 8. Switch normally open (NO) parking brake (S200)
2. Hydraulic oil filter 9. Relay parking brake (K314)
3. Valve block, accumulator charging valve 10. Control unit general (ECU 790)
4. Accumulator 11. Indicator light in switch parking brake (S107)
5. Switch parking brake (S107) 12. Control unit general (ECU 790)
6. Solenoid valve parking brake valve (Y642) 13. Control unit terminal (EDU 795)
7. Parking brake unit
1 5
3
P2
DS
M
OL
SP
2
D
PP
PL M
D6 LS
OL
SP
D
O
4
O
LS
AC DS
K P2
PP
M
AC PP
KM
10 9 8 7
009617
1. Hydraulic oil pump 6. Accumulator charging valve
2. Parking brake valve 7. Parking brake unit
3. Switch normally closed (NC) parking brake (S200) 8. Hydraulic oil filter
4. Solenoid valve parking brake (Y642) 9. Hydraulic oil tank
5. Valve block 10. Accumulator
6 Pull the fixing screw out so that the brake pads can be angled out
and removed.
NOTE
The screw does not need to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with pure denatured alcohol.
9 Install new parking brake pads.
10 Press the fixing screw back.
NOTE
To avoid turning the adjustment screw as well it must be
held still when tightening the lock nut.
17 Refit the cover to the calliper.
18 Test the operation of the parking brake.
function description
The wheel brakes are cooled by means of hydraulic oil being pumped
through the brake unit.
Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, hydraulic oil filter, valve block, and wheel brake units.
The hydraulic oil pump pumps oil (from the tank) which is cleaned in
the oil filter, to the hydraulic functions of the machine. Part of the return
oil from the valve block is directed through the drive axle brake units,
cooling the brakes, and back to the tank.
5
C
C
2 3, 4
D
P
SPOL
007819
1. Hydraulic oil pump 4. By-pass valve in valve block
2. Hydraulic oil filter 5. Wheel brake
3. Valve block
component position
1 2
6 5 4
007817
1. Hydraulic oil pump 4. Wheel brake
2. Valve block 5. Hydraulic oil filter
3. Distribution block 6. Hydraulic oil tank
5 Steering
5 Steering........................................................................................................... 3
5.2 Power-assisted system .............................................................................. 4
5.2.6 Link arm ................................................................................................. 9
5.2.11 Sensor, steering wheel angle ................................................................ 9
5 Steering
mm mm mm mm mm mm
Steering, general
page
–
One machines with reversible operator's seat the steering angle with
directional control valve, reversible operator's seat, is changed when
operating with the operator's seat turned to the back so that the steer-
ing wheel angle and steering angle correspond.
description
3
5
LSO
O
P T LS
4 C
2
L R
6
007820
3
5
LSO
O
P
6 6
R
D6 P T LS
7 4
ECU790 C
L R
2
9
D7 8 8
1
10
009608
1. Hydraulic oil pump 6. Limit switch, seat forwards (S720-1) and seat back-
wards (S720-2)
2. Hydraulic oil filter 7. Control unit (ECU 790)
3. Steering wheel 8. Solenoid valve steering forward (Y636-1) and steering
back (Y636-2)
4. Steering valve 9. Directional control valve
5. Valve block 10. Steering cylinder
NOTE
The standard steering wheel always has priority over joystick
steering or mini-wheel. As soon as a steering wheel movement is
made, then the joystick steering or mini-wheel is disengaged.
9 D3 10
D1 D4
3 12
ECU792
5, 13
D2 6 D2
7
LSO
11
O
P
P1 P2 P
LS LSP LS
TP
2 C T
T1
A B L R
007822
1. Hydraulic oil pump 8. Steering cylinder
2. High pressure filter 9. Feedback lever steering: sensor, wheel angle (R807)
3. Valve block 10. Steering wheel
4. Potentiometer, lever steering (R825) mini-wheel 11. Steering valve
(R825)
5. Control unit (ECU 792) 12. Sensor steering wheel angle (B770)
6. Solenoid valve, steering right (Y615-1) Steering left 13. Control unit (ECU 792)
(Y615-2)
7. Control valve
position
2 4 7 8
P2
DS
M
OL
SP
1
D
PP
PL M
D6 LS
OL
SP
6 AC
K DS
LS
O
O
P2
5 M
PP
AC PP
KM
15
14 12 11 10
13
009618
13
3. Hydraulic oil pump for mini-wheel/lever steering 11. Hydraulic oil filter
5. Solenoid valve, steering right (Y615-1) 13. Solenoid valve (Y636-1 and Y636-2)
Check the control arm pivot joints, shafts and the screws which hold
the control arm shafts.
007918
Check that lever steering and the mini-wheel are disconnected when
the steering wheel is turned.
Also check that the steering angle sensor is securely fixed to its brack-
et and that the multi-function levers are secured, by undoing the lower
part of the steering wheel panel.
6 Suspension
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 4
6.2.1 Steering axle cradle ............................................................................... 5
6.2.2 Wheel spindle ........................................................................................ 6
6.2.3 Wheel hub .............................................................................................. 7
6.3 Tyre and rim system ................................................................................. 10
6.3.1 Tyres .................................................................................................... 20
6.3.2 Rims ..................................................................................................... 21
6 Suspension
mm mm mm mm mm mm
Suspension, description
page
–
6.2 Suspension
Suspension, description
page
–
The steering axle cradle is attached to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on swivelling king pins. The king pins can be turned to enable
steering. The wheel spindles support the bearings for the wheel hubs,
to which the wheels are fixed.
4
1 2 3 4 5
5
1
2
3
007811
11 10 9 8 7 6 11 10 9 8 7 6 007818
DCD 200-250
DCD 280-300
1. Steering axle cradle
2. Fixing lug 1. Steering axle cradle
5. Rim 4. Tyre
NOTE
Do not lift under the steering axle.
4 Re-measure the distance between the frame and steering cradle.
Record the measurement.
5 Calculate the difference between the two measurements. The dif-
ference must be max. 3 mm.
007842
007859
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.
retightened.
F. Check friction torque as below:
The lower limit with no play will be reached when tightening
the bearing nut until no play could be felt when trying to wob-
ble the wheel.
The upper limit could be checked with a spring balance which
gives the maximum friction torque, the friction torque should
be approximately 19 Nm.
Max 8 kg
510 mm
009580
Wind a cord a few times around the wheelbolts before the wheel is
mounted and pull with the spring balance. Read the scale when hub is
rotated.
6 Fit the lock washer and outer lock nut.
7 Tighten with at least 250 Nm or as hard as is needed to bend the
lock washer in the closest groove.
8 Fill the bearing casing with grease and fit it.
9 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring's lip with a small screwdriver to facilitate the air
to escape. Grease until grease comes out by the seal.
NOTE
Work carefully so as not to damage the seal.
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.
009177
retightened.
F. Check friction torque as below:
The lower limit with no play will be reached when tightening
the bearing nut until no play could be felt when trying to wob-
ble the wheel.
The upper limit could be checked with a spring balance which
gives the maximum friction torque, the friction torque should
be approximately 19 Nm.
Max 8 kg
510 mm
009580
Wind a cord a few times around the wheelbolts before the wheel is
mounted and pull with the spring balance. Read the scale when hub is
rotated.
6 Fit the lock washer and outer lock nut.
7 Tighten with at least 250 Nm or as hard as is needed to bend the
lock washer in the closest groove.
8 Fill the bearing casing with grease and fit it.
9 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring's lip with a small screwdriver to facilitate the air
to escape. Grease until grease comes out by the seal.
NOTE
Work carefully so as not to damage the seal.
DANGER
Always block the wheels on the side of the axle where
no work is to be done before positioning the jack. Al-
ways secure the jack to prevent it from sliding out of
position.
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
The tyres are the machine's contact with the ground, the tyres absorb
rough surfaces and act as suspension.
The drive axle is exposed to great stresses during operation, and the
stresses increase if the drive wheels' rolling circumference differs. It is
important that the tyres on the drive axle are of the same model, type
and make, and have similar wear and the correct air pressure.
Read the safety instructions before working with the tyre and rim, see
section Tyre and rim system, safety page 10.
DANGER
Never stand directly opposite the tyre when deflating
or inflating. Components from the rim may release
and shoot off when the pressure changes.
(drive axle)
Read the safety instructions before working with the tyre and rim, see
Tyre and rim system, safety page 10.
Removing
1 Machine in service position, see section B Safety.
2 Lift the machine under the drive axle by the wheel in question.
Support under the drive axle in a safe and adequate manner.
3 Deflate both tyres on the side from which the tyre shall be re-
moved.
If the tyre is in good condition, release the air through the valve.
DANGER
In twin wheel installation, both tyres must be deflated,
or the inner tyre could explode when the outer one is
removed.
If the tyre or rim is damaged, deflate the tyre by drilling a hole in the
tread.
4 Loosen the wheel nuts.
005123
007881
6 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting by the lifting equipment.
005124
NOTE
The spacer ring weighs approx. 20 kg.
9 Lift the outer wheel away and position it safely so that it does not
fall or move.
10 Secure the inner drive wheel with lifting equipment.
007879
11 Remove the spacer ring between the outer and inner drive wheel.
NOTE
The spacer ring weighs approx. 20 kg.
12 Remove the inner drive wheel and position it safely so that it does
not fall or move.
007880
Installing
1 Make sure that the installation surfaces (position A) on the hub
and wheel are clean and free from grease and paint.
2 Lift the inner wheel into place with lifting equipment. Rotate the
wheel so that the guide lug enters the groove on the hub, this
work will be easier if the hub grooves are aligned towards the top
and bottom.
NOTE
The inner ring is not split.
007880
4 Lift the outer wheel into place with lifting equipment. Rotate the
wheel so that the guide lug enters the groove on the hub.
007883
NOTE
The outer ring is split. Rotate the ring so that the opening
ends up in front of the groove on the hub.
007884
6 Place clamps and nuts on the wheel bolts. Where applicable, also
washers.
NOTE
Do not forget the retainer for the inner tyre's valve extension.
7 Remove the lifting equipment.
007878
8 Tighten the wheel nuts alternately, start at the guide heels and
work outwards to prevent the spacer rings from becoming wrong-
ly aligned.
9 Tighten the wheel nuts alternately in turns with increasing torque
to 350 Nm.
10 Inflate the tyre with air, 1 MPa, see Tyres, inflating page 20.
11 Lower the axle and remove the jack.
12 Test-run the machine and check that the wheels are installed se-
curely.
13 Check-tighten the wheel nuts with torque 350 Nm.
007885
Read the safety instructions before working with the tyre and rim, see
Tyre and rim system, safety page 10.
Removing
1 Machine in service position, see section B Safety.
2 Lift the machine under the steering axle by the wheel in question
with a jack. Support under the steering axle in a safe and ade-
quate manner.
4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove all wheel nuts and clamps.
6 Remove the wheel and position it safely so that it does not fall or
move.
Installing
7 Make sure that the installation surfaces on the hub and wheel are
clean and free from grease and paint.
005124
9 Place clamps and nuts on the wheel bolts. Where applicable, also
washers.
10 Remove the lifting equipment.
11 Fit the wheel. Tighten the wheel nuts alternately in turns with in-
creasing torque to 350 Nm.
12 Inflate the tyre with air, see Tyres, inflating page 20.
13 Lower the axle and remove the jack.
14 Test-run the machine and check that the wheels are installed se-
curely.
15 Check-tighten the wheel nuts with torque 350 Nm.
000383
6.3.1 Tyres
Tyres, inflating
page
–
Read the safety instructions before working with the tyre and rim, see
Tyre and rim system, safety page 10.
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Check that all parts are in place when the tyre pres-
sure is 30 kPa.
NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.
1 Make sure that the lock ring and lock lugs are in the correct posi-
tion before inflating.
2 Connect the compressor with a locking air-chuck to the nipple on
the tyre.
3 Stand obliquely behind the tyre and remain there during the entire
pumping procedure to avoid being hit by pieces of rim if there is
an explosion.
4 Inflate the tyre to the prescribed level, see specifications.
Other inflation pressure may apply when changing tyre or rim ver-
sion, contact Kalmar Industries.
Tyres, changing
page
–
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
During tyre changes, the rims must be checked. Please refer to Rim,
check page 21.
6.3.2 Rims
Rim, check
page
–
DANGER
Perform the following checks to minimise risks of ac-
cidents for all rims that can be dismantled.
Max 0,5 mm
001715
001701
O. Circumference
D. Diameter
5 Check for damage in the areas with high stress concentration.
Checking is done in two steps:
1. The magnetic powder method is used to determine if there's
a crack or not, and where it is.
2. Confirmed cracks are investigated further with penetrating
fluid.
Typical rim damages are circumference cracks, corrosive dam-
age, rust, warping and wear.
001702
001704
3 Wash off penetrating fluid with cleaning fluid part no.
923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.
6 Visually inspect the lock ring groove.
1 2
If the tested area does not indicate linear or point-shaped cracks
in the lock ring groove the rim is approved.
If the crack check indicates linear or point-shaped cracks the rim
should be discarded.
001705
Example of cracks
1. Linear crack
2. Pointed crack
7 Load handling
7 Load handling................................................................................................. 3
7.2 Lifting/lowering ........................................................................................... 4
7.2.6 Mast ....................................................................................................... 8
7.2.8 Chains .................................................................................................... 8
7.2.14 Support roller ....................................................................................... 10
7.2.15 Top support roller ................................................................................. 10
7.4 Side shift ................................................................................................... 11
7.4.4 Side shift cylinder ................................................................................. 14
7.5 Spreading ................................................................................................. 15
7.7 Tilt ............................................................................................................. 19
7.7.5 Tilt cylinder ........................................................................................... 22
7.7.6 Mast ..................................................................................................... 22
7.8 Levelling ................................................................................................... 23
7.9 Load carrier .............................................................................................. 27
7.9.1 Lifting forks .......................................................................................... 27
7.9.2 Coil ram ............................................................................................... 29
7.10 Additional functions .................................................................................. 30
7.10.1 Electric scales ...................................................................................... 30
7.10.5 Side lift attachment .............................................................................. 31
7 Load handling
mm mm mm mm mm mm
The load handling function refers to lifting, lowering, side shifting and
tilting the load for example.
Load handling has been divided into the following sub-functions:
• Lift and lower
007363
• Tilt
007364
• Side shift
007916
• Spreading
007910
• Levelling
• Load carrier
7.2 Lifting/lowering
Lift and lower, function description
page
–
Lift and lower means that the mast parts are extended up and down so
that the fork assembly and lifting forks are raised and lowered.
During a lift, the inner mast is lifted by the lifting cylinders. The lifting
chain which is fixed to the carriage (and the outer mast), runs over
sprockets at the top of the mast, this lifts the carriage at the same time
007363
as the inner mast.
The machine can be equipped with a special free lifting mast . The
fork carriage is raised in two stages relative to the inner mast, first with
the free lift cylinder and then with the first stage in the two lifting cylin-
ders. The inner mast is lifted with the second stage in the two lifting cyl-
inders.
The free lift cylinder and the lifting cylinders are pressurised by the
load handling control valve.
The lift and lower is available in two versions depending on how the
function is controlled.
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure which controls the lift and lower function.
•
Electrical servo means that the control levers are electrical and
send voltage signals to the control system to control the lift and
lower function. (Electrical servo is included if the machine is
equipped with reversible operator's position.)
(hydraulic servo)
11
6 10
C 4
9
8
B
7 3, 5
PPD
PP
ACK
b
9
8
P2
D
A
P
a
11
10
2 2 C
1 1
7 ECU796
D
14
6 13
9
D
8
4
12
11
B
10 3, 5
PPD
ACK
PP
b
12
11
P2
D
A
P
a
14
13
2 C 2 C
1 1
007825
1. Hydraulic oil pump 8. Solenoid valve, lift mast (Y6005) lower mast (Y6004)
2. High pressure filter 9. Servo valve
3. Valve block, accumulator charging valve 10. Control valve lift
2
1
3
5
4
P2
DS
M
OL
SP
6
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
7
8
13
12 9
10
11
009611
1. Hydraulic oil pump 8. Lowering brake valve
3. Solenoid valve, lower mast (Y6004) (electric servo) 10. Lowering brake valve
4. Solenoid valve, lift mast (Y6005) (electric servo) 11. High pressure filter
5. Valve block 12. Hydraulic oil tank
6. Lifting mast 13. Accumulator
7. Lift cylinder
7.2.6 Mast
Mast anchorage, checking the bearings
page
–
WARNING
Never work underneath a mast carriage that has not
been secured.
7.2.8 Chains
Chains, checking and adjustment
page
–
With the aim of increasing safety, the lifting chains should be regularly
checked as per the following points.
The entire length of the chains shall be thoroughly cleaned. The check
is performed without load on the forks.
1 The chain may not have increased in length by more than 3%.
Measure across the 25 links that first (and most often) roll across
the chain wheel when lifting. That is where extension is the great-
est. Compare to the value in the table. If the 3% limit is exceeded,
then the chains shall be replaced.
005670
[in] [mm]
New chain Max. length
NOTE
If the chain is slack when the carriage is in its lowest position, the
chain must be tensioned.
007671
9 Adjust the chains so that the carriage lifts evenly in the mast.
• Undo the lock washers (position 1) and remove the old nut
(position 2).
• Lift the chain tensioner (position 4) out of the carriage and re-
3
move the old lock washer.
• Re-install with a new lock washer, chain tensioner, lock
washer and lower nut. Repeat on the other side.
1
NOTE
Only use new lock washers for re-installing.
Side shift means that the lifting forks are moved sideways. The load
handling control valve pressurises the side shift cylinders, which slide
the forks on the fork trolley sideways, left or right, depending on which
way the control lever is moved.
Side shift is controlled and activated by the side shift control lever. Dur-
ing side shift, the piston side of one of the side shift / spread cylinders
007916
is pressurised. Pressure from the piston side of the first cylinder is
transferred to the rod side of the other cylinder and compresses the
other cylinder.
Side shift is available in two versions depending on how the function
is controlled.
• Hydraulic servo means that the control lever is supplied with hy-
draulic pressure which controls side shift.
•
Electrical servo means that the control levers are electrical and
send the voltage signal to the control system to control side shift.
(hydraulic servo)
6
8
C 4
7 B
3, 5
PPD
PP
ACK
b
D
9
A
P
a
2 C
007826
1. Hydraulic oil pump 6. Control lever, side shift
2. High pressure filter 7. Control valve side shift
3. Valve block, accumulator charging valve 8. Side shift cylinder
4. Accumulator 9. Side shift cylinder
5. Valve block, reduction valve
7 ECU796
D
6
9 11
D
8
4
10
B
3, 5
PPD
ACK
PP
b
D
A
P
a
12
2 C
007827
1. Hydraulic oil pump 7. Control unit hydraulics (ECU 796)
2. High pressure filter 8. Solenoid valve, side shift left (Y6020), side shift right (Y6021)
3. Valve block, accumulator charging valve 9. Servo valve
4. Accumulator 10. Control valve side shift, spreading and levelling
5. Valve block, reduction valve 11. Side shift cylinder
6. Control lever, side shift 12. Side shift cylinder
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
9
8
009612
1. Hydraulic oil pump 6. Side shift cylinder
Check visually that the cylinders are straight and that the mounting
points and welding seams are intact.
007849
7.5 Spreading
Spreading, description
page
–
007910
should be different.
When both spreading and side shift are installed, the same hydraulic
cylinders are used for side shift as for fork spreading.
Spreading is available in two versions depending on how the function
is controlled
• Spreading with hydraulic servo means that the control levers are
supplied with hydraulic pressure which controls the fork spread-
ing.
•
Electric Servo means that the control levers are electric, and send
voltage signals to the control and monitoring system to control the
spread function.
(hydraulic servo)
6 9
8
C 4
9
7
B
3, 5
PPD
PP
ACK
b
D
A
P
a
2 C
007828
1. Hydraulic oil pump 6. Control lever spreading
2. High pressure filter 7. Control valve spreading
3. Valve block, accumulator charging valve 8. Flow distributor
4. Accumulator 9. Spreading cylinder
5. Valve block, reduction valve
7 ECU796 12
D
11
6
9
D
8
12
4
10
B
PPD 3, 5
ACK
PP
b
D
A
P
a
2 C
007829
1. Hydraulic oil pump 7. Control unit hydraulics (ECU 796)
2. High pressure filter 8. Solenoid valve spreading in (Y6019) out (Y6018)
3. Valve block, accumulator charging valve 9. Servo valve
4. Accumulator 10. Control valve spreading
5. Valve block, reduction valve 11. Flow distributor
6. Control lever, spreading 12. Spreading cylinder
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
7
10
9
009613
1. Hydraulic oil pump 6. Spreading cylinder
3. Solenoid valve spreading out (Y6018) (electrical servo) 8. High pressure filter
7.7 Tilt
Tilt, description
page
–
Tilt means angling the mast in relation to the machine. Control valve,
load handling, pressurises the tilt cylinders which extend and angle the
mast in relation to the machine. Tilt is controlled with control lever, tilt.
Tilt is available in two versions depending on how the function is con-
trolled.
007364
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure which controls the tilting.
•
Electrical servo means that the control levers are electrical and
the send a voltage signal to the control system to control the
tilting.
C 4
8
7 9
B
3, 5
PPD
PP
ACK
b
9
D
A
P
a
2 C
1
009122
7 ECU796
D
6
9
D
8
4
12
10
B
3, 5
PPD
ACK
PP
b
11 12
VB C1
D VA C2
A
P
a
2 C
007831
1. Hydraulic oil pump 7. Control unit hydraulics (ECU 796)
2. High pressure filter 8. Solenoid valve, tilt in (Y6011) tilt out (Y6010)
3. Valve block, accumulator charging valve 9. Servo valve tilt
4. Accumulator 10. Control valve tilt
5. Valve block, reduction valve 11. Load holding valve
6. Control lever tilt (R8072) 12. Tilt cylinder
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
10 7
009614
1. Hydraulic oil pump 6. Tilt cylinder
3. Solenoid valve, tilt out (Y6010) (electrical servo) 8. High pressure filter
NOTE
Other tilt cylinder anchorage variants may be found, apart from
the ones shown here.
7.7.6 Mast
Mast anchorage, checking
page
–
7.8 Levelling
Levelling, description
page
–
007917
pended via a hydraulic cylinder that moves the fork vertically through
a sleeve secured to the assembly.
With central levelling the front section of the fork assembly is levelled
(turned) around the centre line of the assembly, four degrees up or
down.
• Hydraulic servo means that the control levers is supplied with hy-
draulic pressure which controls the levelling.
•
Electrical servo means that the control levers are electrical and
send a voltage signal to the control system to control the levelling.
C 4
B
3, 5
PPD
PP
ACK
b
8
D
A
P
a
2 C
007832
1. Hydraulic oil pump 5. Valve block, reduction valve
2. High pressure filter 6. Control lever, levelling
3. Valve block, accumulator charging valve 7. Control valve levelling
4. Accumulator 8. Levelling cylinder
7 ECU796
D
6
9
D
8
4
10
B
3, 5
PPD
ACK
PP
b
11
D
A
P
a
2 C
007833
1. Hydraulic oil pump 7. Control unit hydraulics (ECU 796)
2. High pressure filter 8. Solenoid valve levelling down (Y6022) up (Y6023)
3. Valve block, accumulator charging valve 9. Servo valve
4. Accumulator 10. Control valve levelling
5. Valve block, reduction valve 11. Levelling cylinder
6. Control lever, levelling
2
1
3
5
4
P2
DS
M
OL
SP
D
PP
PLD M
LS
6
P
OL
SP
D
O
O
LS
AC DS
K P2
PP
M
AC PP
KM
8 7
009615
1. Hydraulic oil pump 6. Levelling cylinder
The load carrying lifts any load. There are several ways to lift a load,
e.g.:
• Lifting forks, normal and inverted
•
Coil ram.
•
Side lift attachment.
5
6 007841
DANGER
Damaged lifting forks must be replaced.
NOTE
Surface cracks and wear must not be dealt with using weld-
ing.
5 Forks which have been hot-straightened must be heat treated
again (carried out by an approved firm).
mm
mm
gk
GOC
CLL
W
n e d e w S y b g n uj L 1 8 1 4 3 E S
B A seirts u d nI ra mla K
aP M
mm
gk
A
H
D
N/ S
Q
1
4
3
007840
5
NOTE
The mast should stand vertical and fork carriage centred against
the mast when weighing, calibrating and zero adjusting (reset to
zero).
1 Run the fork carriage up and down a few times to remove any
mechanical stresses.
2 The machine should be operated a few minutes before zero ad-
justing (reset) and weight calibration occurs.
3 To select function for calibration, first navigate to the service
menu. Then press Enter.
000056
000060
The code determines the service menu that will be activated
(Diagnostic test, Initiation or Calibration).
5 Select SCALE by scrolling with the arrow keys (1 and 2) and con-
firm with Enter.
SCALE
000803
6 Unload and slightly lower the fork carriage slowly until approxi-
mately 1m above ground. Then, reset the scale to zero by press-
CALIBR 1(2)
600 ing function key in menu 1(2).
SCALE 600
WITHOUT LOAD (mV)
000804
The side lift attachment has been designed for easy, safe and rapid
handling, low weight and ease of maintenance.
Both of the attachments’ corner pieces are telescopic and suspended
from the main beam by means of springs, which enables 195 mm lev-
elling to both sides for the connection to leaning containers. A hydrau-
lic cylinder between the attachment and the carriage allows ±600 mm
side-shift
A hydraulic/mechanical system ensures that the container are locked
via Twistlocks onto the attachment prior to lifting.
An electrical safety system prevents the locking and release of the
twist-locks if the attachment is not correctly positioned against the con-
tainer. The system also prevents lifting if the twist-locks are not either
completely locked or released.
A lamp panel displays alignment, locked and released container re-
spectively.
Twistlocks, checking
page
–
1 2 3
DANGER
Make sure that the engine is off when working on the
Twistlocks.
6 5 lock nut.
4 Clean the area around the sensor for alignment.
1. Sensor unlocked Twistlock
2. Sensor contact 5 Press in the alignment pin so that the head is flush with the
3. Sensor locked Twistlock spreader beam's underside. Check the distance to sensor align-
4. Lock guide ment, distance should be 5±1 mm. Adjust as needed
5. Lift pin
6. Contact pin NOTE
The alignment pin should move easily and spring back com-
pletely.
6 Check that the lock guide and lift pin can move freely.
7 Fit a pry bar between the lift pin (pos. 5) and the lock guide (pos.
4) and check the clearance max. clearance: 1–1.5 mm.
8 Turn the Twistlocks to locked position and check lift pin wear.
Change the lift pin if needed.
9 Repeat steps 1–10 on all four Twistlocks.
m
Max. 4 mm
m
0
.7
in
M
002311
DANGER
Material fatigue, reduced strength.
Fatal danger!
NOTE
Twistlocks are heavy. Take care when removing.
2 Test for cracks within the marked area on the pins without re-
working or damaging the part.
3 If the lift pins show signs of cracking, they must be replaced with
new ones.
002313
1 Check that the contact pins in the corner boxes can move up and
down freely. The contact pins should spring down when they are
not loaded.
2 Check that the sensor is free from dirt and damage.
3 Turn the starter key to position I and check that the LED on the
sensor has gone out.
4 Lower the clamp onto a container and check that the contact in-
dication lamp lights up.
5 Lift the container up a bit so that the contact indication lamp goes
out.
007782 6 With the container lifted, check how much movement is needed
1 2 in the contact pins to detect contact (the LED on the sensor lights
up). The movement should be 3 – 4 mm.
Right-hand side
1. Sensor, contact 7 If necessary, undo the locknut and screw the sensor in/out until
2. Contact pin the distance between the sensor and contact pin is 5±1 mm.
1 2
007919
Left-hand side
1. Sensor, contact
2. Contact pin
1 Check that the sensors are free from dirt and damage.
2 Turn the starter key to position I and check that the LED on the
sensor for unlocked Twistlocks has gone out.
If necessary, undo the locknut and screw the sensor in/out until
the distance between the sensor and indicator plate is 5±1 mm.
3 Check that the Twistlock Open indication lamp is lit.
4 Lower the clamp over a container and lock the Twistlocks.
5 Check that the LED on the Locked Twistlock sensor is lit.
If necessary, undo the locknut and screw the sensor in/out until
the distance between the sensor and indicator plate is 5±1 mm.
007783
6 Check that the Twistlock Locked indication lamp is lit.
1 2
Right-hand side
1. Sensor unlocked Twistlock
2. Sensor locked Twistlock
1 2
007920
Left-hand side
1. Sensor unlocked Twistlock
2. Sensor locked Twistlock
8 Control system
8 Control system
mm mm mm mm mm mm
R
1 2 3
4 5
007801
A
A. Function keys
B. Display
C. Alarm indicator
Function keys
R The function keys (position A) are used to navigate inside the menu
1 2 3 system of the information, settings and diagnosis menus.
They are also used to enter values into the system and to confirm error
codes.
000693
4 5
• Function key 1 1 : scroll anti-clockwise in the menu system and
enter value 1.
Operating menus
50
When the machine is started, the operating menu containing engine
speed, ground speed, current gear (during inching, or when the clutch
is not engaged, gear positions 1-3 are not displayed), time and fuel
level is displayed. This menu is shown until another menu is selected
82 ˚C or an event-controlled menu is shown (e.g., in case of error code of
type “WARNING” and “STOP”). Menus are selected using the function
2.4 bar keys for arrow right and arrow left. For each press of the key the dis-
play changes to the next menu. The Reset (R) function key can be
held depressed to quickly return to the original display.
-/+
60 ˚C
This section describes the information that can be obtained from
- +
28.7 V each operating menu. The figures are shown with example data.
2 L/H
1430 km NOTE
+
300 h Menu availability depends on machinery configuration.
12 L/H
The following operational menus are accessible for assisting opera-
(+/-) 1.2 tors:
75 t • Operating menu
007359
Service menu
The service menu is the gateway to the machine's diagnostic system.
By pressing “Enter” and entering different codes, different parts of the
service menus are accessible. The code to access the diagnosis men-
us is 11111, while the code to access the settings menus requires spe-
cial authority (contact Kalmar Industries with any questions).
000056
8.2 Monitoring
Monitoring functions, general
page
–
• Speed limitation
• Service indicator
000056
3 Enter code for resetting service indicator.
The code is obtained via Kalmar Industries Support.
1 23
4 5 NOTE
000060
If an information error code is deleted with Reset (R), this is not dis-
Example of automatic display figure played again until the system is re-started.
8.4 Diagnostics
Diagnostic test, general
page
–
000916
Workshop manual there are more detailed descriptions of each diag-
nostic menu.
The diagnostic test is divided into the following groups:
• Control unit ECU 790, ECU 790, menu overview page 10.
• Control unit ECU 792, ECU 792, menu overview page 11.
• Control unit ECU 793, ECU 793, menu overview page 11.
• Control unit ECU 796, ECU 796, menu overview page 11.
• History for error codes, Last alarms, description page 12.
The diagnostic test varies between the different control units as to
what type of diagnostics can be carried out, but the following alterna-
tives are possible:
• View inputs – means that the inputs can be checked (digital and
analogue).
• View outputs – means that the outputs can be checked (digital and
analogue).
• Control outputs – means that the outputs can be checked and
controlled (digital and analogue).
2 Press .
000056
1 23
4 5
000060
DIAGNOSTICS
000916
DIAGNOSTICS ECU793
DIAGNOSTICS ECU796
LAST ALARMS
007891
DIAG ECU 790 1(3) DIAG ECU 790 2(3) DIAG ECU 790 3(3)
DIAG ECU 792 1(3) DIAG ECU 792 2(3) DIAG ECU 792 3(3)
007887
8.4.3 ECU 793
ECU 793, menu overview
page
–
ECU793 D M
E
F S
007888
8.4.4 ECU 796
ECU 796, menu overview
page
–
DIAG ECU 796 1(3) DIAG ECU 796 2(3) DIAG ECU 796 3(3)
A history of the latest error codes generated can be seen under this
menu. If the same error code is generated several times this is count-
ed and the number of faults is shown on the display. The time counter
time for when the error code was last generated is also displayed.
Select diagnostics and Last alarms as per Diagnostic test, work in-
struction page 9. This display indicates if Last alarms is selected.
LAST ALARMS Press function key to proceed.
000995 The 10 latest error codes are displayed in chronological order (with er-
ror code number), number of error codes and relevant operation time
for the last error code of this type received.
If only one error code is saved there is only the menu for that fault and
the last menu “Clear all alarms”. So the number of menus under Last
alarms is dynamic. Max. number of error codes saved is 10.
1 Latest active error codes (1, latest) in chronological order.
LAST ALARMS 1(13)
ALARM NUMBER 354
COUNTER 11
16.01.2007 10:58
009350
009355
7 Latest active error codes (7, latest) in chronological order.
LAST ALARMS 7(13)
ALARM NUMBER 601
COUNTER 3
16.01.2007 10:58
009356
8 Latest active error codes (8, latest) in chronological order.
LAST ALARMS 8(13)
ALARM NUMBER 610
COUNTER 1
16.01.2007 10:58
009357
11 Latest active error codes (11) for engine. If more than one code,
LAST ALARMS 11(13) scroll the error codes by pressing the function key 5 .
ENGINE ALARM 1(X)
SPN: 110
FMI: 10
009360
Volvo TAD750VE.
Shown if no saved error codes exist and after reset. If there are no er-
13(13) ror codes from the KCS system, only menus 11-13 are displayed.
NO ALARMS
009364
accessories
Frame, body, cab and accessories,
page
–
description
The machine consists of frame, body and cab.
The frame (chassis) is the machine's structural part and is made of re-
sistant steel.
The body comprises wings, engine cover, tanks and other parts
mounted on the frame.
The cab is built separately and isolated from the frame using heavy-
duty rubber dampers. The operator's seat, steering wheel and control
for hydraulics can be adjusted for optimal individual operating position.
Effective insulation results in minimal vibrations and a low sound level.
The machine is equipped with a heating and ventilation system, and
can be equipped with an optional air conditioning system.
WARNING
Each case of mechanical damage to the cab can in-
volve risks as strength is changed.
WARNING
Never work underneath a cab that is not tipped over
its balance point or secured in another way.
Danger of crushing.
WARNING
Avoid walking on the engine cover without anti-slip
protection.
Slipping danger.
WARNING
The strength of the roof window can be significantly
reduced with exposure to substances that contain:
• Aromatic hydrocarbons
• Ketones
• Esters
• Chlorinated hydrocarbons
CAUTION
All reworking of the roof window is forbidden (e.g.
making holes, cutting or widening existing holes).
1 2 3 4A 5
R
1 4 5
14 2 3
7A
4B 7B
006910
13 12 11 10 9 8
4A Steering wheel
4B Joystick or mini-wheel
5 Multi-function lever
6 Parking brake
8 Arm rest
9 Driver’s seat
10 Accelerator pedal
11 Brake pedals
12 Clutch pedal
Inching pedal
30 31 32 33
22 Switch for extra working lamps
TO DE
AU MO
30 Spare
31 Spare
32 Spare
35 36 37 38 39 40 41 42 43
35 Warning lamp for exhaust cleaning (particle filter)
R
40 Indicator lamp for direction indicators
1 2
R
3
41 Display for the control and monitoring system, KCS
4
42 Alarm indicator for control and monitoring system, KCS
5
43 Ignition switch
006903
51 52 53 54 55 56 57 58 59
51 Switch for reversing alarm cutout
007728
55 Spare
57 Spare
58 Spare
59 Spare
1. Operational menu
1 50
2. Operational menu engine
3. Operational menu transmission and electrical system
4. Operational menu service interval
8 2
82 ˚C 5. Operational menu scale
5
(+/-) 1.2
75 t
007899
158 t
8 2 11 9 8 7 1. Reversing alarm
5. Fire extinguisher
The fire extinguisher is normally located on the left front fender,
but can also be located on the right front fender or inside the cab.
If the machine is equipped with a fire extinguisher, it should be of
1, 8 6 10 3 5 4 9 8 type ABE according to EN 3 parts 1, 2, 4 and 5. This type of extin-
009491
guisher can put out fires in both solid organic materials and fluids.
Suitable fire extinguishing equipment can be ordered from Kalmar
Industries.
6. Seat belt
7. Buzzer in cab to indicate alarm or forgotten action, for example,
leaving driver’s seat without applying the parking brake.
9c 9a 9. External mirrors :
Used to give improved visibility when operating and load handling.
9a shows the concealed area in front of the machine
9b shows the concealed area beside/behind the machine
9c shows the concealed area behind the machine
9.3 Seats
Seats, general
page
–
The seat's function is to give the operator a good sitting position and
contribute to a good work environment. The cab's seat can be adjust-
ed in several ways, and meets high comfort standards.
Machines with cab alternative Spirit Delta can be equipped with
reversible or swivelling operator’s seat .
NOTE
Other types of driver’s seat may occur.
1 2 • air suspension
• head restraint
8 6
006825
Isringhausen 6500)
The seat is equipped with:
• air suspension
• air adjustable lumbar support
• mechanically adjustable seat cushion angle
• mechanically adjustable damping
• horizontal suspension (can be shut off)
• seat belt, 2-point
8 • head restraint
• adjustable arm rest, right
2 3 6 1 5 7 4 9
Controls Isringhausen 6500
1. Adjustment, length
2. Adjustment, seat height
3. Adjustment, seat angle
4. Adjustment, backrest angle
5. Adjustment, damping
6. Seat heater
7. Adjustment, lumbar support
8. Adjustment, armrest right
8. Adjustment, armrest left
Actimo XXL)
The seat is equipped with:
• air suspension (height)
• air adjustable lumbar support
• mechanically adjustable seat cushion angle
8
• mechanically adjustable seat length
• mechanically adjustable damping
• integrated horizontal suspension
• head restraint
• adjustable arm rest, right
10
• adjustable arm rest, left
2
5
4 • seat heater
6 • integrated compresso
003710
3 1 7
Controls Grammer Actimo XXL
1. Adjustment, length
2. Adjustment, seat cushion
3. Adjustment, seat height
4. Adjustment, seat angle
5. Adjustment, backrest angle
6. Adjustment, damping
7. Yard damping
8. Adjustment, lumbar support
9. Adjustment, armrest right
10. Adjustment, armrest left
function description
A truck with standard equipment has a heater unit (cabin/defroster)
connected to the engine cooling system and provides heat when the
engine is warm. The heating unit comprises fan and elements for
warming the air. The air is distributed through integrated ducts in the
cab’s interior equipment and can be guided to defroster or floor for ex-
ample. In FlexCab cab the air is distributed through three adjustable
air nozzles and can be guided to defroster or floor for example.
Climate control available in different types:
Air conditioning includes the parts presented in the illustration and en-
sures the driver’s cab climate is as comfortable as possible. Air condi-
F
tioning function is to:
• heat the air when it is cold
2 • dehumidify the air when it is damp
4 • clean the air of impurities
D
C • cool the air when it is hot
• defrost (defroster function)
E E
The unit is controlled with switches and controls on the instrument
3 panel.
The unit’s fan is controlled in steps 0-I-II-III (with the fan control). With
climate control ECC the fan is variable 0–100%.
6 A B
5 1
G
000762
component position
1 2 3 4 5 6
O E
7 8
AUT MOD
9 10
11
18
17 16
15 14 13 12
007900
1. Sensor outdoor temperature ECC 10. Sensor, after heat exchanger ECC
CAUTION
Authorisation is required for repair of the climate con-
trol system.
NOTE
The climate control system does not work at temperatures below
approx. 0 °C since the pressure in the refrigerant circuit is too low.
If the pressure in the refrigerant circuit becomes too low, the low
pressure monitor cuts off electric power supply to the compres-
sor's magnetic clutch, which means that the air conditioning stops
functioning.
Shall be performed during continuous use every week from early
spring to late fall as well as in winter, during longer periods with high
humidity.
In winter during cold and dry periods with low utilization, the compres-
sor shall operate a few minutes every week so that rubber hoses, cou-
plings, gaskets and axle seal are lubricated.
1. Check that the condenser is not clogged – if necessary clean the
condenser flanges with compressed air.
2. Check that the compressor cuts in and out without problems.
3. Check that the outlet for the cooling coil's condensation water is
not clogged.
4. Check that there is no refrigerant leakage. If there is a leak, oil and
gas often form a dirty, dusty patch.
5. Start the engine and activate the cooling function with setting
maximal cooling. With ECC: Select Cool mode and the tempera-
ture at min.
Let the engine run at minimum 1500 r/min. (At temperature below
approx. 0 °C the cooling function does not start due to low pres-
sure in the system.)
6. With AC: Set the fan control to position I or II.
With ECC: Set the fan to medium speed.
7. Check after 10 minutes operation that there are no bubbles in the
receiver dryer's sight glass. (Bubbles shall only appear when the
compressor starts and stops).
NOTE
If there is a blockage in any of the cooling circuit compo-
nents, and during long-term operation, some components
can become very hot (mainly the hoses in front of the con-
denser). Burn danger!
2. All hoses and components on the pressure side (from the com-
pressor to the expansion valve) shall be warm.
3. All hoses and components on the suction side (from the evapora-
tor to the compressor) shall be cold.
4. Check the expansion valve. If it is frosty or cold on the inlet side it
means that it is defective or clogged, that circulation is restricted
or stopped on the pressure side.
5. Check that the compressor is engaged and disengaged normally.
Run the cabin fan at low speed and let the compressor run at high
speed. When the temperature in the outlet reaches 0°C, the com-
pressor is disengaged via the thermostat or ECC, and is re-con-
nected when the temperature has risen to about 3-7°C. (If the
compressor is not disengaged, there is a risk that the evaporator
could ice up and the cooling effect would be reduced.)
WARNING
In case of a rupture of a cooling hose or leakage of the
plant – turn off the unit immediately.
WARNING
The electric fans may injure the hands.
NOTE
Reliable checking of the amount of refrigerant using the sight
glass can only be done when the ambient temperature is above
approx. 15°C.
There is a sight glass on the left side of the condenser, on the pipe
leading to the condenser. In the centre of the sight glass, there is a col-
oured dot for moisture indication. The indication is normally GREEN.
If the indicator turns YELLOW, there can be moisture in the system
(this can occur if the system is not evacuated before the refrigerant is
added, or if refrigerant has leaked out).
NOTE
Reliable inspection of the sight glass is difficult without in-
spection mirror.
Inspection can also be performed by loosening the condenser's
outer protective casing, see step 3-5.
4 Carefully lift the left side of the condenser's outer protective cas-
ing.
19. Open the valve on the pressure side and let the compressor suck
from the tube. Watch the sight glass. At the beginning, the fluid is
heavily mixed with bubbles. The longer the compressor sucks,
less bubbles appear and the fluid becomes clearer. If the bubbles
suddenly disappear, the cooling thermostat has probably disen-
gaged. Bridge the thermostat using a cable directly from the con-
nection 24 V or wait until the thermostat engages again. Continue
to fill until correct refrigerant amount has been reached.
NOTE
By-passing directly on the compressor's connecting magnet
can lead to compressor damage, caused by incorrect refrig-
erant amount.
Close the valve on the suction side and then the valve on the tube.
Loosen the service hoses from the compressor and fit the protec-
tive caps. Check for leaks according to step 11 or with a special
leak detector.
20. In case of overfilling, the pressure and temperature slowly in-
crease until the high pressure monitor cuts off the current to the
compressor solenoid. This is due to the refrigerant rushing around
in the system without being evaporated or condensed in the con-
denser. The result is that the cold in the cooling coil is lost and
high heat is generated in the condenser. In addition, a heavy flow
of bubbles can be seen in the sight glass. Return to step 2.
21. In case of insufficient filling or lack of refrigerant, there are bubbles
in the sight glass - return to step 2.
A fresh air filter is also available as an option on the Spirit Delta cab
with AC or ECC .
NOTE
Make sure that the filter insert is installed with the arrow marking
facing the correct way.
6 Install the front casing.
6 Remove the M8 nuts for the condenser's two front rubber damp-
ers.
On the cab, there are wipers for front and rear windscreens as well as
the roof windows. Its function is to clean the windows and to maintain
good visibility from the cab.
The wiper arm is attached to the wiper motor's shaft over a splined
3 cone. The shaft is made of hardened steel and the wiper arm’s attach-
ment is made of mild die cast material.
When installing, it is very important to make sure that the splines are
free from metal filings etc. Also, the nuts shall be tightened so hard that
the splines are pressed into the attachment and act as a flange. Hold
still the wiper arm when installing so that the torque isn’t transmitted to
the motor, which may be damaged (16–20 Nm tightening torque).
2
1
001878
1. Wiper front
2. Wiper roof
3. Wiper rear
Drier, check
–
Check that:
1. the motors operate correctly, with no unwanted noise.
2. the wiper arms press the wiper blades against the windows.
Change them if they have signs of damage or considerable wear.
3. the wiper blades are undamaged. Change them if they are dam-
aged or worn.
4. the screenwasher function spreads screenwasher fluid over the
windows in a satisfactory manner. If necessary, top up the screen-
washer fluid and adjust the washer nozzles.
NOTE
It is important that the right type of lamp is used for each area.
See section F Technical data.
The following lighting is fitted to the machine:
10, 12, 15 8 7 9 13
11, 14
1, 2, 3, 4, 6 16
3, 4, 5
007909
1. Rear lights, red 9. Interior lightning
2. Brake light 10. Working lamps, cab roof, rear edge, 2 lamps
3. Driving direction indicator 11. Working lamps, mast, 2 lamps
4. Position light 12. Extra working lamps cab roof rear edge, 2, 4 or 6 lamps
5. Headlight 13. Extra working lamps for cab roof front edge, 2 lamps
8. Rotating warning light 16. Extra working lamps between tilt cylinders, 1 lamp
NOTE
It is important that the correct type of lamp is used for each area.
Please refer to insert F Technical data.
7 4
5, 6
3, 5
007902
1
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
007792
E
Overview, cab windows
A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Side windows front
Roof window, check
–
Check that the roof window is not damaged or cracked. Change a de-
fective roof window at once.
DANGER
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
The cab has a level floor with a bracket for the operator's seat. It is sus-
pended in a cab undercarriage via heavy-duty rubber pads located on
the bottom of the cab. This is to minimise vibration from the frame to
1 the cab. Each rubber pad mounting has a rubber bushing and a bolt.
3
003206
1. Cab frame
2. Door
3. Suspension of cab
4. Cab undercarriage
9.10.2 Doors
Doors, check
page
–
The cab can be tipped to an angle, over its centre of gravity, pivoted
around the left-hand side suspension, assisted by a hydraulic cylinder.
The hydraulic oil pressure is generated by a hand-controlled pump
with an integrated reset valve for tipping up or down.
On the right-hand side mounting are locking devices which secure the
cab to the frame and can be easily released for tipping the cab.
WARNING
C Never work underneath a cab that is not tipped over
its balance point or secured in another way.
Danger of crushing.
Preparations:
• Set the gear and direction of travel selector in neutral position.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
• Check the cab for any loose items.
• Close the doors.
Tilting
1. Turn both lock handles (position C) so that they end up in their out-
er position to release the cab from the frame.
001536
Electric tilting
1. Turn both lock handles (position C) so that they end up in their out-
er position to release the cab from the frame.
2. Set the pump valve (position B) in right hand position.
3. Use the control buttons to raise the cab to end-position. Press in
both buttons at the same time.
Electric lowering
9.12 Frame
Chassis, component position
page
–
There are attachment points in the frame for engine, gearbox, drive ax-
le, steering axle, fuel and hydraulic tanks and cab, mast and body
parts.
5
3
1 7
007940
1. Frame front section
2. Frame rear section
3. Member pair
4. Mounting, rear wings
5. Drive axle mounting
6. Steering axle mounting
7. Mast mountin
9.13 Body
Body, safety
page
–
WARNING
Avoid walking on the engine cover without anti-slip
protection.
Slipping danger.
Body, description
page
–
The function of the body is to be part of the chassis. There are wings
to deflect dirt, footsteps and hand rail to facilitate access to the chas-
sis, engine cover to deflect dirt and objects from the engine compart-
ment and a counterweight to balance the machine's lifting capacity.
3 2 4
1 5 007904
1. Fenders front
2. Fenders rear
3. Engine hood
4. Counterweight
5. Battery compartment
9.13.4 Counterweights
Counterweights, check
page
–
WARNING
Factory fitted counterweights adapted to truck char-
acteristics.
3 • Pipes, between the main unit and the distribution block, and be-
tween the distribution block and the grease nipples.
• Grease nipples, by grease points
At the pump unit, it is possible to adjust the frequency and duration of
the lubrication intervals.
007935
The central lubrication unit is supplied with current when the parking
brake has been released.
1. Pump unit
2. Safety valve NOTE
3. Distribution block
Central lubrication does not lubricate the propeller shaft’s univer-
sal joint, the brake pedal, fork shanks, mast wheels and support
rollers. These must still be lubricated during preventive mainte-
nance.
1
2 1 Check that no grease has been forced out through the safety
valve (position 2).
3
If grease has been forced out through the safety valve, there is a
stop in the system. Localise the pipe which has become blocked
by feeling the unions at the distribution block. A blocked hose will
4
stay under pressure and the union will be stiff.
NOTE
If several distribution blocks are series connected, a blocked
pipe will remain under pressure all the way back to the dis-
tribution block.
2 Turn the ignition key to position I.
3 Turn the pump manually and check that the indication pin (posi-
tion 3) on the distribution block moves in and out.
To operate the pump, undo the cover and press the manual op-
5 eration switch (position 5).
If the indication pin does not move, although the pump runs, the
007941
9.15 Paint/coatings
Paint/coatings, description
page
–
NOTE
Touching up, the surfaces to be touched up must be carefully
cleaned.
Please contact Kalmar Industries for information about other surface
treatment and material colours.
10 Common hydraulics
10 Common hydraulics....................................................................................... 3
10.2 Security valves ........................................................................................... 5
10.3 Tanks and accumulators ............................................................................ 6
10.3.2 Accumulator ........................................................................................... 7
10.4 Pumps ........................................................................................................ 8
10.5 Hoses, pipes and valves ............................................................................ 9
10.5.2 Main valve ............................................................................................ 11
10.6 Temperature control, cleaning and hydraulic oil ....................................... 14
10.6.2 Hydraulic oil cooler .............................................................................. 15
10.6.7 Breather filter hydraulic oil tank ........................................................... 16
10.6.8 High-pressure filter .............................................................................. 17
10.6.9 Hydraulic oil ......................................................................................... 19
10 Common hydraulics
mm mm mm mm mm mm
Pressure plate
There's a pressure plate on the machine, stamped with the most im-
portant pressures. The pressure plate is located on the right side of the
frame in front of the steps.
Pressure levels vary with the equipment and are therefore unique to
each machine. When checking pressure, the pressures should match
the pressure plate.
1 2 3
4
5 4
007889
An accumulator drain valve is installed in the return pipe from the ac-
cumulators. The accumulators shall be drained with these controls be-
fore working on the hydraulic system. For draining the hydraulic
system, see section B Safety.
To verify that the accumulator pressure has been released, measure
with a pressure gauge on the pressure check connection by the accu-
mulator charging valve (see Measuring nipples, component position
page 11).
007894
A
A. Accumulator drainage valve control
A. Filling
B. Level glass
C. Breather filter
B
009454
10.3.2 Accumulator
Accumulator, check
page
–
1 Start the machine and let it run at idling speed (until the accumu-
lators are charged).
2 Switch off the engine and turn the ignition key to position l.
3 Apply and release the brake several times and count the number
of times the brake can be applied before error code for low brake
pressure is shown in display.
It must be possible to apply the brake 8 times before error code
for low brake pressure comes on.
If error code for low brake pressure comes on sooner then the ac-
cumulator is faulty and should be investigated further.
10.4 Pumps
Pumps (fixed displacement), general
page
–
The hydraulics in the machine are supplied as standard from two fixed-
1 displacement gear wheel pumps. These are driven by splined shafts
from the engine. The pump shafts are carried in plain bearings that are
lubricated by the flowing oil. The pumps have the following functions:
1. Pump 1 supplies the lift function.
2. Pump 2 supplies the steering, other function related to load hand-
ing and the hydraulic accumulators, which in their turn supply the
brake system and the load handling servo circuit.
The priority valve in the valve block ensures that there is always
pressure for steering. The remaining fluid flow is available for load
2
handing.
When the accumulators are fully charged and the lifting function
lifted to its end position, the capacity of both pumps is used for
007893
Hydraulic oil pumps, standard version. 3. Pump 2 supplies also lever steering/mini-wheel .
1. Hydraulic oil pump for lifting function
The pumps are assembled to the gearbox power take-off.
2. Hydraulic oil pump for steering, load handling,
brake system and servo circuit for load handling
component position
The control valve (comprising a valve block and a control section with
directional valves), in the standard version, is acted on above the hy-
draulic servo from the driver station.
1
P2
DS
M
OL
SP
D
PP
2 PL M
3 D6 LS
OL
SP
4 D
O
O
5 AC
LS
6 K DS
P2
PP
008990
7 PP
M
AC
KM
1. Ventilblock
2. Lift and lower section
3. Inlet section
4. Tilt section
5. Side shift section
6. Spreading section
7. Levelling section
1 8. Servoventil
9. Solenoid valves
a. Solenoid valve, lower (Y6004)
P2
DS
M
OL
SP
2 PL M
3 D6 LS
SP
OL
c. Solenoid valve, spreading out (Y6018)
4 D
5 LS
O
O
d. Solenoid valve tilt out (Y6010)
AC
6 K DS
P2
PP
e. Solenoid valve, levelling down (Y6022)
7 PP
M
Located on the main valve are a number of measuring nipples and ad-
justment options for certain functions. Most measuring nipples are lo-
cated on the valve block and an occasional one on the direction
valves.
For pressure values for the various measuring nipples, see the pres-
sure sign (located beside the cab tipping control for the machine).
P2
10
DS
M
OL
SP
D
PP
PL M
D6 LS
OL
SP
D
O
O
LS
9 AC
K DS
P2
PP 5
8 6
009610
M
AC PP
KM
NOTE
Read the safety instructions for oil before work, see section B
Safety
Pressure data sign – Increase the engine speed to about 1800 rpm. Read the
pressure again. The difference should not exceed ±1.0 MPa.
Lift (P2)
– Increase the engine speed to about 1100 rpm.
– Activate the lift to its end position and continue to activate the
function.
– Read the pressure off and compare with the permissible
pressure on the pressure sign.
– Increase the engine speed to about 1800 rpm. Read the
pressure again. The difference should not exceed ±1.0 MPa.
function description
The hydraulic system oil is cleaned through a high pressure located af-
ter each hydraulic oil pump.
The cooling system lowers the temperature of the hydraulic oil in the
vehicle. The cooling system consists of a hydraulic oil cooler with sep-
arate temperature-controlled electric fan, located in the service brake
cooling circuit.
The hydraulic oil pump pumps the oil (from the tank) via the high pres-
sure filter and the valve block, which is then cooled in the hydraulic oil
cooler. An electric cooling fan increases the air flow through the cooler
when the temperature needs to be lowered. A thermal bypass valve
directs the hydraulic oil past the cooler and direct to the tank if the tem-
perature is below 55°C. When the oil temperature is above 65°C, all
oil is directed through the cooler.
The temperature sensor starts the electric fan if the oil temperature is
above 60°C and shuts the fan off if it is below 50°C.
˚C 5
C 7
3 4 8
M
D
6
P
SPOL
C
2
9
1
007912
component position
3
4
5
2 8 7 6
009609
1. Thermal by-pass valve 5. High pressure filter
009570
There are three hydraulic oil filters in the engine compartment. Two
large and one smaller (one large filter is added for option mini-wheel/
joystick steering). The method describes changing a filter but applies
to all filters.
NOTE
Read the safety instructions for oil before work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filters.
NOTE
The filter brackets are heavy, loosen them carefully.
8 Remove the filter inserts
9 Fit the small O-ring, which is in the packaging, onto the new filter.
If uncertain, compare to the old filter insert.
NOTE
Use only original filters.
11 Fit the support ring (white) and O-ring (black), which are in the
packaging with the new filter, into the groove in the top of the filter
cover.
NOTE
It is important to fit the support ring under the O-ring as illustrated.
12 Grease the top of the filter cover (on the side) with universal
grease EP2.
13 Fit the filter cover.
14 Start the engine and check that no leakage occurs.
15 Switch off the engine.
16 Check the hydraulic oil level, see Hydraulic oil, level check page
19.
NOTE
The hydraulic oil level is checked with the lifting carriage fully low-
ered and the mast fully tilted inwards
The condition of the hydraulic oil must be checked with oil tests aimed
at avoiding unnecessary wear and unnecessary oil changes. The in-
tervals for oil tests are advised in the service schedule. Oil tests are
carried out as per instructions from the relevant institution or oil suppli-
er.
Threshold value for efficient oil is 18/14 according to SS-ISO 4406
“Hydraulic equipment - fluids - Method for classifying impurities
through fixed particles”.
NOTE
Read the safety instructions for oil before work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
NOTE
Ensure that the sealing washer on the drain plug is also fit-
ted.
9 Fill with new hydraulic oil until the level is in the centre of the level
glass.
10 Fit the filler cap.
NOTE
Ensure that the sealing washer on the drain plug is also fit-
ted.
11 Common electrics
11 Common electrics
mm mm mm mm mm mm
Under the function common electrics one finds electrical functions that
are common to several of the machine's main functions. For example,
voltage feed and CAN-bus.
5. Control switch
5 2
4 3
007905
11.2.2 Fuses
Fuses, checking
page
–
IMPORTANT
Risk of cable damage and fire in cable harnesses!
The electrical system has two main circuits (30 and 15 supplies),
please refer to Electrical distribution, general page 10. The main cir-
cuits are protected several times over, with main fuses and circuit fus-
es.
Main fuses
The main fuses splits the machine's voltage feed in smaller parts to
maintain as many functions as possible in case of damage in the ca-
bling.
The machine's electrical system has main fuses in the battery com-
partment on the frame, 4 pcs. 25 A. They cut off all electric power, ex-
cept fuse 7 in fuse holder F58-3 and fuse number 8 in fuse holder F58-
4.
Checking and changing main fuses:
1. Turn off the main electric power with the battery isolator.
2. Remove the plastic cover.
3. Check and change fuses as needed. Fuses are rated at 25 A.
4. Turn on the electric power again.
1
007936
Circuit fuses
Circuit fuses are grouped in fuse holders that are located in the elec-
trical distribution box in the cab. The electrical distribution box is locat-
ed behind the operator’s seat in the cab.
There is a fuse sign beside the distribution box which describes each
fuse.
A B C D
007482
Fuses
A. Fuse holder F58-1
E
B. Fuse holder F58-2
C. Fuse holder F58-3
D. Fuse holder F58-4
E. Fuse holder F56 (engine alternative Cummins)
Checking and changing fuses:
1. Turn off the main electric power with the battery isolator.
2. Remove the cover over the electronic box.
3. Remove the cover from the fuse holder.
4. Check that fuses are intact. Change when needed.
007937
Check if necessary.
The fuse chart provides information about each fuse.
11.3 Batteries
Start battery, component position
page
–
WARNING
Battery electrolyte contains corrosive sulphuric
acid.
NOTE
A discharged battery freezes at -5 °C.
NOTE
If the acid values are different between batteries they must be
charged separately.
The fluid level must be at the height of the upper section of the round
white plastic ring seen down in the battery when the cover is screwed
off.
NOTE
Only use distilled water for topping up.
Check that the battery terminals are clean and free from dirt. If needed,
grease the battery terminals with terminal grease.
11.4 Alternator
Alternator, component position
page
–
007767
Volvo TAD750VE
007767
Cummins QSB6.7
The voltage before the ignition switch is usually called 30 volts. It is al-
ways approx. 24V, even if the ignition is switched off (ignition key in
position 0).
The voltage after the ignition switch is usually called 15 volts. This is
at 24V only if the ignition is switched on (ignition key in position 1). Oth-
erwise this voltage is 0V.
Power supply takes place with cable harnesses (cables) which are
drawn across the truck.
Communication takes place via twinned pair signal cable (30 rpm).
1 2 3 4 5 6 7
9 10 11 12 13 14 15
009109
16 17
1 2 3 4 5 6 7
9 10 11 12 13 14 15
008571
16 17
1 2 3 4
7 6 5
007908
1. Control unit, steering (ECU 792) 5. Control unit transmission (ECU 793)
2. Control unit hydraulics (ECU 796) 6. Control unit Volvo engine (ECU 794)
3. Control unit general (ECU 790) 7. Control unit Cummins engine (ECU 794)
11.6 Communication
Communication, general
page
–
007764
ECU 794 ECU 793
1. Segments
2. CAN bus drivetrain
The CAN bus consists of two twisted paired leads (twisted pair).
Redundant CAN bus means that every control unit has two connec-
ECU 790 EDU 795 ECU 796 tions for communication. The CAN bus is connected in series between
CAN R CAN L CAN R CAN L CAN R CAN L
the control units. This means that the CAN bus can handle loss of a
segment. If several segments are lost, some control unit(s) lose con-
tact with the network and work independently, often with limited capac-
High+/Low- ity to perform its task.
007765
ECU 792
The signals can be checked with diagnostic menu.
Communication with Control unit engine EDC (D794) and Control unit
EDU 795 transmission (ECU 793) is separated from the redundant CAN bus.
The signals can be checked with diagnostic menu.
007766
D Error codes
Error codes
mm mm mm mm mm mm
Workshop manual
Information is found in the Workshop manual.
For information how to order Workshop manual, see section
A Foreword.
E Schematics
Schematics
mm mm mm mm mm mm
Workshop manual
Information is found in the Workshop manual.
For information how to order Workshop manual, see section
A Foreword.
F Technical data
Technical data
mm mm mm mm mm mm
Data
Power acc. to ISO 3046 (net 181 kW at 2300 rpm 194 kW at 2200 rpm
power) 182 kW at 2200 rpm
Voltage 400 V
Output 13.5 kW
TE17000
4 Brakes
Service brake system - affected Wet Disc Brake - Drive wheels
wheels
5 Steering
Steering system Hydraulic servo
Tyre type, front and rear Air inflated. Spare and replacement tyres shall be from a manufacturer approved by
Kalmar Industries.
Bulb 3 Ba72
Volumes
For oil types see Recommended oils and lubricants page 9.
1.2 Engine, fuel system DCD 200-220 DCD 240 DCD 250-300
Coolant volume 40 l 40 l
Oil volume 35 l
9 Frame, body, cab and ac- Condenser with two fans Condenser with four fans
cessories
Refrigerant air conditioning R134a
Volume refrigerant 1700 g (see plate for air conditioning) 2200 g (see plate for air conditioning)
dimensions
008073
DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD
200- 200- 220- 220- 240- 240- 250- 250- 280- 280- 300- 300-
12 12LB 12 12LB 6LB 9LB 12 12LB 12 12LB 12 12LB
Lifting capacity
Dimensions
Truck length without 6060 6070 5710 6320 6675
forks (L [mm])
Height, basic machine 3450 3270 3450 3270 3270 3270 3450 3270 3650 3415 3650 3415
(H6 [mm])
DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD DCD
200- 200- 220- 220- 240- 240- 250- 250- 280- 280- 300- 300-
12 12LB 12 12LB 6LB 9LB 12 12LB 12 12LB 12 12LB
Height at cab tilt, max. - 3800 - 3800 3800 3800 - 3800 - 3800 - 3800
(OHG) (T1 [mm])
Operating weight [kg x 29,8 29,8 31,2 31,2 29,4 31,9 32,9 32,9 37,7 37,7 39,0 39,0
10 3]
Axle pressure front, 46300 49500 4990 5190 53800 61500 64500
(with classed load) [kg] 0 0
Axle pressure rear, 14800 16200 1440 1690 17400 18700 20000
(without load) [kg] 0 0
Axle pressure rear, 3500 3700 3500 4000 4100 4200 4500
(with classed load) [kg]
10 Common hydraulics
Hydraulic oil AV 32
SS 155434 AV 46
NOTE
Oil filters must always be replaced in conjunction with oil chang-
es.
The interval for engine oil changes assumes that the sulphur con-
tent in the fuel does not exceed 0.5%.
*) API CH-4 or CI-4 is approved for markets outside the EU/EEA.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
CES = Cummins Engine Standard
Other matters
Grease Use a universal grease of the type EP acc. to NLGI Grade 2 (EP2) with 3-5% molybde-
num sulphide content for all lubrication sites except glide plates.
Slide grease Use a Kalmar approved lubricant for glide plates. Ordered from Kalmar spare parts de-
partment.
0.65 kg cartridge for grease gun, part no. 923110.0360, and 5 kg can, part no.
923595.0003.
Tightening torques,
page
–
recommendations
The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tighten-
ing torque should be reduced by approx. 5%.
For mild surfaces (hardness below 200 HB), washer shall be used un-
der both bolt head and nut. Alternatively, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication ac-
cording to the table below.
State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M-thread
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
UNC-thread
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
couplings
Pipe and hose coupling
mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
mm inch Nm
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170
Flange coupling
42x2 330
48x2 400
Unit explanations
page
–
Unit Abbreviation
Newton metre Nm
Kilowatt kW
kilojoule kJ
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km
Torque
Power (W = J/s)
Energy (J = Nm)
Horsepower/torque
Temperature
Flow factor
Unit cm m km in ft yd mile
1 mm = 0,1 cm - 1 mm = 0,001 m
Unit g kg t oz lb
Explanation
page
–
Term Description
AC Air Conditioning. Heating unit with manual control of heating, cooling, dehumidification
and air flow.
Accumulator Reservoir that stores (accumulates) pressure for hydraulic functions for example.
Attachment The part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidising, in daily use rust inhibitor.
Operating hydraulics All load handling functions, i.e. lift and lower, tilt, side shift, spreading and levelling.
Wheelbase Distance between the drive and steering axles.
Bar Unit for measuring pressure.
Battery disconnect switch Interrupts the current from the battery.
Central lubrication An automatic system for lubricating a preselected number of lubrication points.
Daily inspection Those actions that must be carried out every day to ensure the functionality of the ma-
chine.
Decitonne A tenth of a tonne, unit of measurement of the machine’s lifting capacity.
Displacement The oil volume that the pump can supply per pump revolution.
Display “Window” that shows digital information on the steering wheel panel in the cab (with
KCS).
Operating time Number of hours that the machine has been operating, shown on the operating time
gauge in the cab.
Drive axle Driving axle which receives torque from the drive line.
Drive line Parts of the machine that contribute to the power transmission; engine, torque converter,
gearbox, propeller shaft and driving axle with differential and hub reduction.
ECC Electronic Climate Control. Climate control system with automatic control of heating, cool-
ing, dehumidification and air flow.
ECU Electronic Control Unit
EDU Electronic Display Unit
Electrolyte level Fluid level in the battery cells.
Electric servo Load handling hydraulic components receive control signals from electro mechanical
controls.
Expansion tank Reservoir for coolant.
Fixed displacement Pump with fixed pump volume.
FMI Fault Message Identifier.
Forks Lifting device that lifts the loads.
Fork mountings Mountings for forks, mounted on the lift assembly.
Main fuse Located beside the battery. Interrupts the current to every system in the machine.
Hydraulic oil Oil for hydraulic system. See specifications in the Operator’s manual.
Hydraulic oil pump Pump in the hydraulic system.
Term Description
Hydraulic system System that uses oil pressure to transfer power to different functions.
Hydraulic servo Load handling hydraulic components receive control signals from mechanical controls.
Hanging load Raised load.
Indicator Manual “sensor”, indicates, for example, if a filter is blocked and needs replacing.
KCS Kalmar Control System. An electronic control and monitoring system that monitors and
handles certain systems in the machine which require KCS, e.g., certain engine and
transmission alternatives.
Piston The bar that slides into the piston cylinder and is affected by hydraulic pressure.
Refrigerant Liquid/gas in the Air conditioning. May only be handled by authorised trained personnel.
Lifting capacity Indicates how great a load the machine can lift.
Lifting point Attachment point for lifting device when lifting objects.
Lift assembly Lifts the load, located on the mast.
Low emission engine Engine with low emissions of dangerous substances. Manufactured according to regula-
tions.
Solenoid An electro magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used for controlling items, for example, releasing pressure and thereby
lowering a mast or a fork. See also control valve.
Machine model Machine type. Given as, for example: DCD 200-300. See also type designation.
Environmental waste Used oil filters etc. must be handled according to applicable national laws and regula-
tions.
Torque converter Hydraulic, stepless clutch.
Counterweight Weights adapted to the machines lifting capacity to provide counter weight when lifting.
Hub reduction Type of final drive (often with drive wheels) that reduces the speed and increases the
torque from the driveline.
Pilot oil pressure A low control pressure, for example, to a valve.
Planetary gear Type of gearbox with the gears in constant mesh.
Product alternative One of several alternatives selected for the machine, i.e. engine alternative.
Progressive steering Faster steering wheel movements give greater steering response.
Proportional valve An electro magnetically controlled valve. If a current is applied, the valve is activated pro-
portionally to the size of the current. In everyday speech, a stepless valve, as opposed to
an on/off valve. On the gearbox valve housing for example.
Frame members Bearing members of the frame.
Recirculation Circulation in a closed system.
Serial number Unique machine designation. On the machine plate.
Service position How the machine must stand securely before service is started.
Servo A small movement by the user gives a greater effect, i.e. power steering.
Servo pressure A low control pressure to control a higher pressure, for example to a valve.
Side shift The forks are moved parallel sideways.
Levelling The forks are inclined if the load is on an uneven surface.
SmartLink Software for handling KCS (Kalmar Control System).
Term Description
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Spreading of forks, that is, changing the internal distance between the forks.
Mast Carriers of unit and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which empties automatical-
ly while driving.
Steering axle Wheel axle with steering.
Buzzer Audible alarm for gaining the driver’s attention.
Option Optional equipment for the machine.
Tilt The mast is tilted forwards or backwards.
Top-lift Attachment. See attachment.
Transmission oil Oil for the gearbox and torque converter. See specifications.
Transport safety for the vehicle Precautions before machine transport.
Twistlocks Two detent bolts, one in each corner of the unit, which slide into corresponding holes in
the container and are twisted to lock the container into position when lifting.
Type designation Indicates type of machine and capacity. See also machine model.
Maintenance Periodic maintenance operations so that the machine functions safely and lasts well.
Variable pump Pump with adjustable flow speed
Variable displacement Controllable volume (capacity) in a pump.
Valve slide Moveable section of the valve. Determines the path of the oil.
Wet brakes Brake friction plates in an oil bath.
Index
page
–
Brakes 4 Brakes 4
Cab structure and suspension 9 Frame, body, cab and accessories 9.10
Conditions A Foreword -
Coolant B Safety -
Copyright A Foreword -
Driveline/axle 3 Driveline/axle 3
Engine 1 Engine 1
Environment B Safety -
Feedback A Foreword -
Frame, body, cab and accessories 9 Frame, body, cab and accessories 9
General A Foreword -
General B Safety -
General B Safety -
Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4
Noise B Safety -
Oils B Safety -
Refrigerant B Safety -
Safety and emergency equipment 9 Frame, body, cab and accessories 9.2
Solvents B Safety -
Steering 5 Steering 5
Storage A Foreword -
Suspension 6 Suspension 6
Transmission 2 Transmission 2
Vibrations B Safety -